What's New in Processing March/April 2015

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18.2

The complete control solution in “Hygienic Design�.

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Keeping promises.

Taking a stance.

Values, not words.

Your ideas are our inspiration. We dedicate ourselves to meeting your requirements and desires. We listen carefully, offer creative input, and together find innovative solutions, ensuring all your needs are met. Together, we will think one step ahead. You can count on us. www.pepperl-fuchs.com

Your automation, our passion.

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18.2

On the Cover...

Highly efficient meat portioning using PC Control

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MARCH/APRIL 2015 Volume 18.2

Editor Debbie Scott debbiewnip@mweb.co.za

Advertising Sales Manager Roxanne Bredenkamp roxannewnip@mweb.co.za

Published by What’s New in Publishing cc ck 2000/037639/23 P O Box 2214 Primrose 1416 South Africa

Tel: 0861 PROCES (776 237) Fax: 086 723 5321 www.whatsnewinprocessing.co.za Printed by: Raptor Print Views expressed in this publication do not necessarily reflect the opinions of the publisher.

Copyright reserved on all material

VI Entwicklung und Produktion GmbH in Irschenberg, Germany, makes machines and production lines for all areas of meat portioning and processing – ranging from meat tempering to transferring cut portions to packaging machines. TVI benefits from its own long-term expertise in the industry as well as from the performance and flexibility of the Beckhoff controllers and drivers it installs on its machines to meet the steadily rising requirements of customers with regard to process speed and accuracy.

TVI machines are flexible meat processing centers that can be adapted to any portioning task with standard modules and customer-specific programs. Because the continuing consolidation of the food processing industry exerts enormous pressure to drive down costs, process efficiency is becoming increasingly important. Thomas Völkl, managing partner of TVI, references his company’s motto to explain the rising requirements his company’s solutions must meet: “Our machines portion any kind of red meat, of any consistency and cut type. We ensure optimum results in terms of weight accuracy and minimization of product waste along with maximum efficiency in terms of labor and energy.” Just as important is the ability to offer comprehensive solutions for meat portioning and processing. This spectrum, says Völkl, comprises provisioning, tempering (warming up frozen meat and lightly freezing fresh meat), portioning (slicing, portioning, shingling), traying (manual or automatic), inspecting, and transferring the product to the packaging machine. Maximum energy efficiency is ensured in two ways: On one hand, servo drives replace most pneumatic and hydraulic actuators; this dramatically reduces the energy consumption of the machines. One the other hand, TVI’s shock freezers are extremely efficient. Since the meat is removed seconds before the portioning process, the tempering crust needs to be only 2 to 3 millimeters thick and not 5 to 10 millimeters as is the case with most other systems. This cuts the energy consumption by roughly 80 percent.

Machine expertise reinforced with flexible control technology The use of energy-efficient and precisely controlled servo drives as well as pneumatic valves, which are optimized through precise and fast control, are just two examples of how demanding customer requirements can be fulfilled with PC-based control. This applies to individual machines as well as entire lines, as Thomas Völkl explains: “Thanks to our modular concept, we can build production lines with great flexibility from our individual components such as shock freezers, portioning machines and automatic tray fillers with tray dispensers and leftover disposal units. The modules are then linked with matching conveyors. By selecting the right individual components we can adapt the line to meet each customer’s requirements. The control technology from Beckhoff has proven to be exceptionally flexible and suitable for all our applications.

The first component in a TVI meat processing line is the CBF Cyclefreeze, a rotary shock freezer. The meat is fed and discharged semi-automatically. Using a flap mechanism, the operator places the meat into one of the machine’s baskets before pulling the drawer back again. The transport chain then advances the next basket. The CX9020 Embedded PC controller with its 1-GHz ARM Cortex™ A8 CPU moves the baskets through the freezer in such a way that the tempered meat is ejected after the specified time has elapsed (for example, 8 minutes). The shock freezer operator interface is implemented via a built-in, customer-specific CP6907 Control Panel that features a stainless-steel bezel and a flush 5.7-inch touch display. The panel is equipped with DVI/USB extension technology that allows it to be installed at a distance of up to 50 meters from the PC. Multi-functional portioning system is the heart of the line At the core of most TVI meat processing centers and located directly adjacent to the shock freezer is the company’s greatest revenue-maker, the multi-functional GMS 500 portioning system. The machine is controlled via a powerful CX1030 Embedded PC and TwinCAT NC I software. The Control Panel is an integrated CP6901, also with a stainlesssteel bezel and a flush 12-inch touch display panel. Four compact AX5206 EtherCAT servo drives and five pole-wound AM3021 synchronous servo motors with AG2210 planetary-gear units ensure accurate motion control. Designed for highly accurate workflows, the GSM 500 carries out the following process steps: • The operator places one or more pieces of meat into a mold.

• The machine rotates the mold to the cutting position and the appropriate piston is activated.

• The meat is perfectly formed and measured in the longitudinal direction.

• The machine portions the meat with no or minimal leftovers.

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18.2 The knife cuts the first slice after a linear unit has determined the slice’s thickness in accordance with the target weight. The machine then continuously cuts the rest of the slices. Immediately after the last cut, the mold revolver moves the next piece of meat into position, and the process is repeated.

At the end of the meat portioning center sits the FPS 500 Euroline traying system, which places the meat into trays for catch-weight or fixed-weight portions.

It consists of three coordinated modules: the MIS 3000-4000 manual inlay area with the TDS 300 tray dispenser, the automatic AIF 500 trayfiller, and the GMI 500 weighing and sorting unit. First, the portioned meat slices coming from the GMS 500 are placed on the conveyor belt of the MIS 3000-4000. From there they are placed into trays either manually or automatically with the AIF 500.

The filled trays then move to the GMI 500, where they are buffered and weighed on a dynamic scale. Portions that are too light or too heavy are automatically pushed to separate buffer conveyors and moved to a rework station.

Trays with correct weights continue directly to the packaging machine. All of these units are again automated with controller and drive technology from Beckhoff, such as the CP6901 12-inch control panel, four AX5206 EtherCAT servo drives and five AM3021 synchronous servo motors with AG2200 planetary-gear units.

Flexible and precise servo drives The performance of servo drive technology from Beckhoff is evident in a wide variety of motion control tasks. In the GSM 500 portioning system, servo drives and servo motors ensure that the mold revolver and the spacer plate are rotated into exact position. The entire meat processing center operates with a wide range of rotating and pivoting movements – in the conveyor belts or the toothed-belt feeders for the trays, for example.

A special new development at TVI is the AIR 250 inlay machine with four servo axes that move a flap for leftovers, the conveyor and a socalled spring belt, and the toothed-belt feeder for the empty trays. On this machine, TVI also employs the new One Cable Technology (OCT) solution from Beckhoff where the feedback signals and power are directly transmitted via one cable.

This eliminates the need for several wires and connectors on the motor and drive sides, resulting in significant component and commissioning savings.

Thomas Völkl believes that Beckhoff drive technology offers exciting potential for the future: “In our future developments we will integrate

even more safety technology, and TwinSAFE offers a consistent system for drives and I/O with great implementation benefits. Accordingly, we will predominantly employ servo technology from Beckhoff.”

PC Control offers speed and a broad spectrum of applications TVI decided already in 2008 to replace conventional PLC technology with PCbased control systems.

Thomas Völkl explains why: “Back then we ran into performance limitations, particularly when several synchronously operating axes had to be controlled. We initially programmed these applications in C++ and implemented them on an industrial PC. But we realized very quickly that the combination of PC and PLC technology slows the process down unnecessarily.

Switching to an entirely PC-based control system was therefore an easy choice. Also, Beckhoff was the ideal supplier because their system is not only very fast, but open and extremely flexible.” The Beckhoff system also allowed TVI to implement the necessary hydraulics controllers very effectively, adds Völkl. In addition, PC Control works equally well for small applications like the tray dispenser with its single air cylinder, vacuum valve and small control panel as itdoes for complex control tasks.

The flexible Beckhoff I/O system, with over 300 EtherCAT Terminals, opens up a wide range of applications and meets all of TVI’s requirements. Its space-saving design is particularly important for Thomas Völkl: “Since our machines are very compact, the high density of the I/O terminal system is of great benefit for us.

For Völkl, the term systems supplier also covers another important aspect: “Beckhoff delivers the entire control technology pre-assembled in control cabinets as a value-added service. This is a huge benefit for us, because we no longer have to keep these components in inventory.”

New TwinCAT 3 software generation offers higher potential for more efficiency Thomas Völkl believes that the new TwinCAT 3 software generation offers the right tools to increase efficiency: “Having the kind of objectorientation that TwinCAT 3 supports so effectively is essential for making electronics and programming more modular. TwinCAT 3 delivers two major benefits: object-oriented programming requires a lot less effort and it easily accommodates multiple developers’ work on the same project simultaneously. That’s why we will implement TwinCAT 3 on the next generation of our portioning machines.”

Beckhoff Automation (Pty) Ltd. Phone +27 (0) 11 795 2898.

Email: info@ beckhoff.co.za www.beckhoff.co.za

New relay modules for environments with explosive atmospheres

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he product range of the highly compact PLC Interface relay modules now also includes variants for deployment in environments with explosive atmospheres.

These comply with the legally prescribed requirements and approvals according to Class 1, Division 2. Some of the variants additionally comply with the ATEX guideline.

Industrial environments subject to explosive atmospheres require switching components to have very high levels of reliability and safety.

The new relay modules feature RTIII-sealed relays and safe isolation of coils and contacts according to DIN EN 50178.

They are available with screw-in as well as spring-cage connections, facilitating easy installation in crowded switching cabinets.

Voltage distribution is very quick thanks to pluggable bridges that are inserted into the relays’ bridge shafts.

In addition, wiring of the components can be further simplified through the use of adapters when connecting to the system cabling. kevinp@phoenixcontact.co.za

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New oil and gas multivariable transmitter

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he Rosemount 4088 multivariable™ transmitter is a new platform in upstream and midstream oil and gas applications, providing differential pressure, static pressure, and temperature measurement from a single transmitter.

The advanced Rosemount 4088 extended range capability captures flow rate spikes above the upper range limit of the transmitter to account for flow that would have traditionally been missed.

Achieving a high level of measurement accuracy and output efficiency over the life of a well is a huge undertaking, and the Rosemount 4088 multivariable transmitter will help companies meet their objectives.

The transmitter’s extended range capability delivers superior measurement performance for plunger lift measurement

applications over the life of oil and gas wells. Its new sensor technology measures flow rate spikes while still achieving excellent performance over the typical operating range.

By accurately measuring flow that is commonly missed, this extended range capability guarantees the accurate accounting of oil and gas production, potentially saving companies thousands of dollars a year.

As wells mature and process conditions change, maintaining accurate measurement instrumentation is critical to well stakeholders and leaseholders.

The Rosemount 4088 MultiVariable transmitter offers stable performance over the life of the well, ensuring consistent production and minimizing service and equipment costs.

The 4088 provides a reliable and stable signal transmitted through Modbus, BSAP, or MVS; resulting in excellent data accuracy and more effective management of changing well conditions.

The 4088 is typically integrated into a larger oil and gas production network by transmitting data to flow computers and RTUs. The device is designed to easily integrate with Emerson’s flow computer products, such as the ROC, FloBoss™, and ControlWave®, but it can be used with any new or existing flow computer or RTU network that accepts Modbus input.

Michael.Eksteen@Emerson.com

Valves for low and high temperature gas applications

Cables, Wires & Accessories

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HELUKABEL a leading international manufacturer and supplier of wires & cables, custom cables, cable accessories, data, network & bus technology and media technology, as well as pre-assembled cable protection systems for robotics and handling systems.

Helukabel SA offer a massive range of cables and wires to suit your purpose The range consists of - instrumentation, control, data & computer cables, drag chain,servo, motor and feedback cables Heat resistant, rubber, trailing, robotic, chemical resistant, welding, thermocouple / compensating Coaxial, panel, telephone, power, electronic, plus much, much more

A broad range of Cable Accessories, form part of the extensive range offered

by Helukabel This includes Protective Tubing, Sleeving, Compression Glands, Reducers, Enlargers, Braids, Tube Holders, Drag Chains, Connectors and much more

If your exact requirements are not available from our massive standard range, contact us and we will design and manufacture your Cable, Wire, Spiral cable or Harness to your exact requirements.

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ocally designed and manufactured damper valves are specifically used for gas control in low pressure and high temperature gas applications.

The dampers can be manufactured in flanged, wafer or lugged pattern designs in single-door, double-door or oblong vane-type configurations.

Robust in design, the dampers have carbon or stainless steels bodies and disks and the shaft seals can be either PTFE or graphite, depending on the operating temperatures.

The dampers are subject to a leak rate not exceeding 1% of their rated flow and they are available in sizes from 200 mm up to 2 500 mm with flange ratings of up to #600. If required, larger sizes are available on request.

Dampers are ideal for use in the mining, petrochemical, food, breweries, pulp and paper and power generation industries. enquiries@mitech.co.za

Enquire about our exciting New Products

Now with offices in KZN & the Cape

Contact Details TEL: +27 (0)11 462 8752 FAX: +27 (0) 11 462 8638 sales@helukabel.co.za www.helukabel.co.za

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18.2 Speed sensors for drives and axes

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he high switching frequency of 15 000 Hz, as well as the extended temperature range of -32 to 125 °C, make the new MX5 magnetic speed sensors the perfect partner for the detection of rotational speed and direction of rotation on axes, drives and shafts. The detection of both direction of rotation and rotational speed is integrated into one housing.

With fully electronic magnetic measuring cells, the sensors function reliably without contact, even in the case of heavy soiling.

They are ‘magnetically biased’ with an integrated permanent magnet. The ferromagnetic teeth on a toothed wheel alter the existing magnetic field so that a corresponding switching signal can be generated.

The sophisticated housing concept offers different combinations of housing

lengths and connections, such as straight or angled cable outlets and AMP connectors. Toothed wheel modules made of metal are standardised and have a defined tooth width and distance.

The flanged housing offers quick mounting and accurate adjustment of the sensor with only one screw. This reduces phase shift and guarantees precise detection of the toothed wheel.

MX5 sensors can be used to select one or two-channel speed detection. Besides speed, the direction of rotation can also be detected using two channels.

Also, apart from a NPN or PNP switching output, the speed sensor family covers various module sizes of toothed wheels.

The new sensors are adjusted to module 1.25. info.za@ifm.com

Heavy-duty laser contrast sensor solves challenging part-detection applications

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ith the ability to detect up to 2,000 events per second, the Q3X laser contrast sensor provides high-speed, reliable detection of parts, tools, pallets or registration marks with small contrast differences. The Q3X has a small laser spot and is an excellent sensor for reliable part presence, tool-in-place or broken tool detection in stamping and machining centers.

Featuring speeds as fast as 250 μs and a sensing range up to 300 mm, the Q3X is ideal for high-speed packaging and detection applications of small targets, such as registration marks on packaging, or verifying placement of black gaskets and O-rings on machined metal parts.

The Q3X was designed for precise detection in harsh environments. The bright laser spot and digital read-out allow

machine builders to quickly set up the sensor for their application. The metal housing and robust construction means it will survive in their application.

Featuring a unique angled, three-digit display of signal intensity, the Q3X provides high visibility of operating conditions from multiple angles. For an intuitive user setup, the Q3X has two tactile buttons conveniently located below the display.

Designed with robust nickel-plated zinc die cast housing, the Q3X provides superior performance, even in environments with exposure to cutting fluids and oils.

Sensors are also rated to IP67, IP68 and IP69K for enhanced protection to water submergence and high-pressure wash down. rodneyt@retauto.co.za

Now MIMO capable access points can be deployed in hazardous areas

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he iWAP107 is the latest in the iWAP series of ATEX and IECEx approved access point enclosure systems. The new iWAP107 brings the advantages of MIMO technology to hazardous process areas. Previously, WiFi links in heavy process areas have been badly affected by multipath interference created by the abundance of metallic structures causing the signal to scatter before arrival. In contrast, MIMO uses multipath algorithms to increase the range, throughput

and robustness of the data link by capturing the scattered signals and recompiling them. The new iWAP107 enclosure system allows the latest MIMO Access Points from market leaders such as Cisco and Aruba to be deployed in hazardous areas to significantly improve wireless performance and reliability.

The iWAP107 also comes with the revolutionary iSOLATE500 RF galvanic isolators, which makes all the antenna points intrinsically safe. This enables any standard

antenna to be used with the system and allows conventional wiring of RF connections.

Designed for use in ATEX and IECEx Zone 1 hazardous areas, the iWAP107 is a perfect system to allow data to be unlocked from difficult process areas such as oil rigs and heavy petro-chemical sites.

The iWAP107 has already been commissioned for use in deep water production platforms where its gigabit Ethernet capability is vital in providing

the necessary bandwidth. The manufacturers have recently experienced a dramatic upsurge of wireless enquiries in hazardous areas.

The iWAP107 is part of a substantial programme of product development designed to cost-effectively address this growing demand. It’s use of the new iSOLATE500 RF galvanic isolator means far simpler and more cost-effective deployments. sales@extech.co.za

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18.2 Security router with integrated switch

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he new FL MGuard is a security router and network switch in one. Two versions of the FL MGuard are available: The RS2005 provides five unmanaged ports, whereas the RS4004 provides four managed ports plus a DMZ port for the mutual securing of multiple networks.

The DMZ port can be used to connect to a third network, which might run a mail server, for example. This server can be accessed both from the secure LAN side as well as the unsecured WAN side. However, access from the WAN side to the LAN side is blocked thanks to a firewall that monitors and regulated all the incoming and outgoing traffic at each transfer point. The DMZ can also be used for remote servicing of a machine or system.

The built-in network switches are able to handle local switching of small machines and systems, or they can be connected to larger networks.

Rising cost pressures in the industrial sector are causing manufacturers of heavy-duty industrial routers to increasingly pursue all-in-one product strategies, as these minimize installation effort, installation space, and power consumption.

The FL MGuard security routers bring together routing, VPN, firewalls, DMZ, and network switching all within a single housing, which means they are perfectly equipped to meet current demands. kevinp@phoenixcontact.co.za

Horizontal monoblock pump for water circulation

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EO’s XKP series are self-priming centrifugal pumps (with filter) mainly used in water circulation and filtration systems such as water treatment systems, light industries and small and medium swimming pools. The pumps provide stable, reliable and cost-effective pump operation with a low noise action.

With a horizontal monoblock design, the pumps offer a 27m3/h

maximum flow, a 17 m maximum head and are suitable for use in temperatures of up to 35°C. XKP pumps have a plastic pump body, an AISI 304 stainless steel shaft and meet IPX5 protection as well as insulation Class B requirements.

They are available in DN 40 – 63 mm motor sizes. enquiries@raptech.co.za

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18.2 Conventional desuperheaters

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he locally designed and manufactured conventional desuperheaters reduce plant maintenance, are easy to install, and have no moving parts. They are used to reduce the temperature of superheated steam to a predetermined set point within 10ºC of the saturation point of the steam.

All units are designed and manufactured in accordance with ISO 9001 and PED quality approval systems.

The system works by feeding spraywater to a nozzle or multiple nozzles through a control valve. The control valve will receive a signal from the temperature controller indicating the demand for spraywater required to achieve set point temperature. This water is injected through the nozzle into the main steam line, therefore reducing the temperature of the steam.

High pressure water ensures that there is suitable atomisation of the water, which will be absorbed by the steam.

The robust units are easy to maintain and may be mounted in any position. They have a turndown ratio of up to 3:1 and provide an inexpensive and long lasting solution where low turndown is required.

Engineered for each application, they provide accurate control to within ± 1°C of set point. The units are lightweight making them easy to install, and with no moving parts in the steam flow, maintenance is reduced.

The desuperheaters are ideally suited for use in the petrochemical, power generation, pulp and paper, food and beverage and sugar industries. enquiries@mitech.co.za

One for all – a single inductive sensor for three applications

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he new IFS inductive sensor is suitable for industrial, mobile, cooling and lubricating applications. With a large temperature range from -40 to 85 °C and protection rating of IP 65 to IP 69K, it provides reliable detection due to improved sensor tolerances.This newly developed generation of inductive sensors is the first to present one sensor that can be used for three different applications. Whether in factory automation, in applications with coolants and lubricants or in mobile applications – the new ifm technology platform distinguishes itself with universal and permanent usability while

guaranteeing high performance, temperature stability and higher sensing ranges.

Flexible, easy and fast setup of the sensors is via the M12 connection or via a 2 m PUR cable. Increased sensing ranges guarantee reliable detection of the objects. Since only one sensor is required for different applications, stock-keeping is reduced. This new generation meets the user’s increased machine uptime requirements while offering a reliable switching function. All in all, a universal sensor for permanent use. info.za@ifm.com

Quality assurance made easy

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he ability to see the chronological history of a remote station at any time is one of the advantages of the new Ecograph T RSG35 with its redesigned web server. The device sets a benchmark in the category for data recording and quality assurance. With its input configuration of 4/8/12 universal input’s, the Ecograph T offers the possibility of replacing two recorders at a time. Alternatively, the screen recorder is also available with MODBUS RTU/TCP Slave.

Remote access The web server provides complete access and complete parameter configuration externally. Settings can be stored

locally or saved settings can be uploaded to the device. The remote access not only allows current values but also historical data to be visualized on the web server.

The Field Data Manager evaluation software offers users further advantages. The automatic function is configured as a Windows service, for example, so that data is called up in the background. A Microsoft SQL Server or an Oracle SQL database can also be used for data archiving. The essential version, which includes all the important features, is supplied free of charge.

E-mail function The Ecograph T is particularly well-suited to the wastewater

management sector thanks to the integrated e-mail function than comes as standard. It allows alarms and messages generated in outdoor structures to be transmitted to a smartphone

as an e-mail using GPRS, DSL or Ethernet. Mobile access to the web server is also possible if configured appropriately. info@za.endress.com

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18.2 Optimal solutions: for any industry and any application

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hether it’s reliable temperature measurement in steam pipelines at power plants or the exact determination of process temperatures in chemical plants, these temperature assemblies are as versatile as the requirements and specific applications of customers. Both tried and tested methods and the latest in production technology come into play. Thanks to this unique connection, you are provided with not only standard temperature assemblies but also customised temperature measurement equipment.

Highly resistant and gas-tight thermocouples in the OPTITEMP series are highly insensitive to rapid temperature changes and boast good stability in reducing atmospheres. This means that the enormous thermal and mechanical loads occurring on a daily basis in many industries pose no problems. OPTITEMP flue gas thermocouples are used in combustion processes such as those found in the iron and steel industry. They are highly resistant to abrasion. Similar elements can also be used in ovens.

It makes no difference if there are high temperatures, extreme pressures or high

flow velocities: KROHNE meets virtually every need when it comes to temperature measuring technology, ensuring maximum process certainty at the same time.

Thermowells with tapered tips are as much a part of the line as metallic thermowells featuring additional titanium or tantalum casing used, for example, in the event of high chemical exposure. Suitable temperature assembly materials are always selected based on the various process media as regards corrosion and abrasion.

Strength calculations when it comes to customer-specific thermowells can always be performed on an individual basis.

Other features such as the explosion-proof characteristic through intrinsic safety and flameproof enclosures or the SIL compliant design, contribute to the technical reliability of a wide variety of installations. With the compact sensor range they are also able to provide advanced temperature measuring in tight areas due to its small form factor.

Another benefit is no moving parts.

The fast build-in transmitter is already set by factory. salesza@krohne.com

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18.2 Collecting sensor data via IO-Link with durable, machinemountable modules

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he IO-Link box module devices from offer protection class IP 67 and enable the local connection of sensors in the field via simple and cost-effective sensor cables.

This provides straightforward data transfer to an IO-Link communication system. Beckhoff offers a total of 28 module variants in plastic or die-cast zinc housings that cover a wide range of application requirements.

IO-Link box modules offer an extensive IP 67 product range for making cost-effective point-to-point connections directly in the field. The basis for data transmission is the IO-Link protocol, which is a communication technology for sensors and actuators that is ‘below the fieldbus level’ and is standardised according to IEC 61131-9.

These modules supporting IO-Link communication provide benefits particularly when complex sensors must be connected. Previously, Beckhoff already made it possible to integrate up to four IO-Link devices via an IO-Link master, such as with the EP6224 EtherCAT Box (IP 67), the EL6624 EtherCAT Terminal, or the KL6624 Bus Terminal (both IP 20). If such a master is present, the new IO-Link box modules now enable simple integration of further sensor

The IO-Link box modules in protection class IP 67 are available with plastic or diecast zinc housings for a wide range of application requirements

signals, locally in the field via a simple sensor cable and which are then transferred collectively to the IO-Link master.

The comprehensive IP 67 I/O portfolio from Beckhoff is thus extended for even more applications. With a total of 24 bus systems, the IP 67 I/O modules support all common communication protocols, and therefore heterogeneous applications.

The best performance by far, however, can be achieved by using EtherCAT Box modules throughout, so that the full

functionality of EtherCAT can be harnessed without limitation.

Cost-effective and flexible sensor connections, even in extremely harsh environments The IO-Link box modules enable connection of binary sensors as well as complex sensors and actuators.

The connection between the modules and the respective IOLink master is completed through an M12 connecting line (Port Class A). In the case of modules with increased power consumption, an additional voltage infeed is possible (Port Class B). Economical

wiring is offered through the use of unshielded industrial cables.

The modules are designed according to IO-Link specification V1.1; the range of the pointto-point connection is 20 m, according to specifications. No separate IO-Link configuration tool is required, since it is integrated directly in the TwinCAT software system.

The connected IO-Link devices can be universally identified, diagnosed, and if necessary simply replaced without parameterisation having to be carried out again.

Thanks to the compact form factor and different available designs, including the tried and tested plastic housing (EPI) or the extra robust die-cast zinc housing (ERI), the IO-Link box modules can be used in a wide range of application environments.

Binary sensors can be connected to 8- or 16-channel modules with an M8 or M12 screw connection. The universal digital I/O modules with 8 or 16 freely usable input/output channels are highly flexible in use.

The 4 channel analog input box or “combi box” with two analog inputs and two analog outputs can be used to record and transfer analog signals locally in the field. kennethm@beckhoff.co.za

Small-scale barrel sensors ideal for tight spaces

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URCK is proud to announce the addition of new 4mm and 5mm barrel sensors to its existing lineup. The new EG05K and EH04K are 15mm shorter than the standard EG05 and EH04, which allow the new offerings to be used in applications previously not possible. These more compact sensors will benefit the stamping industry, medical device manufacturing and any application where small sensors are a requirement.

The EG05K and EH04K are housed in a stainless steel barrel and come with a high flex TPU cable that can withstand harsh applications, including those involving corrosive chemicals. Offering a 1mm sensing range and full flush mounting, the EG05K and EH04K reduce the chance of damage while still offering the sensing range demanded. The EG05K and EH04K come equipped with a high visibility LED to provide users

a visual indication of the sensor’s status.

The EG05K and EH04K were created in response to customers requesting a solution that met the increasingly compact requirements brought on by the shrinking size of machinery. These new additions provide customers with the shortest M4 and M5 sensors on the market while retaining the robust qualities expected.

The EH04K is available in 2 meters of potted cable, while the EG05K is available in 2 meters of potted cable or with an integral M8 connector. The sensors are IP67 rated, have an operating temperature range from -25° C to 70° C, and offer PNP and NPN configurations for increased application flexibility. rodneyt@retauto.co.za

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18.2 Yokogawa signs extended channel partnership with ICA

A bull’s eye in quality.

Vinesh Maharaj, Sales and Marketing Director Yokogawa South Africa (Pty) Ltd (Back), Johan Louw, Managing Director Yokogawa South Africa (Pty) Ltd (Front, left), Mark Calvert, ICA Managing Member (Front, right)

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okogawa South Africa (Pty) Ltd announces the extension of its partnership with Industrial Control & Automation (ICA) of Pinetown following the recent opening of its regional Sales and Services office in KwaZulu –Natal in February 2015.

“We value the relationship with the team at ICA, and they continue to be our primary channel partner in the country.

We look forward to many years with ICA representing our brand in this region.” says Johan Louw, Managing Director of Yokogawa South Africa. ICA markets Yokogawa field instrumentation such as pressure, flow and analytical applications to customers in the KwaZulu – Natal region as well as Swaziland and Mozambique, with their Front Sales Engineers actively supporting customers with sales advice and application consultation.

Yokogawa’s internal sales team support with quick quotation turnaround, procurement and logistics to deliver the products.

Yokogawa hosts several specialists supporting application advice from its Roodepoort regional headquarters in Johannesburg.

Engineering projects and services related to Yokogawa’s control systems and software are supported directly by Yokogawa’s engineers.

Additionally, local accredited training is an investment made by Yokogawa for the industrial automation industry in KwaZulu –Natal to ensure improvement and availability of a higher skilled labour force.

“ICA has been part of Yokogawa for a long time and our customers know no difference.

The brand representation is unconditional and comes with the full support from Yokogawa.” says Mark Calvert, Managing Member at ICA. ICA is based in Pinetown and provides general advisory and installation services in the Electrical & Instrumentation field for industrial applications.

Christie.cronje@za.yokogawa.com

Paperless recorder – Every measurement counts!

Ecograph T RSG35 Versatile and economical • Up to 12 inputs • Internal memory 128 MB • Ethernet, RS232/RS485, USB, Modbus RTU/TCP Slave • Safe and complete recording and visualization of all process sequences Ecograph T RSG35

R14117* 11–35 pcs.

Price/piece in R

Version for panel mounting

1–3

4–10

11–35

4 × univ. input, Ethernet + USB

R15180 R14573 R14117

4 × univ. input, Modbus + RS232/485 + Ethernet + USB

R18800 R18048 R17484

Mathematics package, 4 × universal input, Ethernet + USB

R19280 R18509 R17930

Math. package, 4×univ. input, Modbus + RS232/485 + Ethernet + USB

R22900 R21984 R21297

*Refer to website for sales and supply conditions.

For technical details and applications visit: www.za.endress.com/e-direct Tel: 0861 363 737 (0861 endres) 24 hr Helpline: 082 443 4214 Service Hotline: 0861 347 378 (0861 ehserv) info@za.endress.com www.za.endress.com

12

18.2 Easy identification options for connectors

I

n facilities and constrained work areas which have a high number of connectors, things can quickly get confusing.

Where does the connector come from?

Where does it lead to?

Does the connector transmit data, signals or power?

ESCHA, the German connector- and housing specialist provides two solutions: Coloured rings as well as label carriers for the clear marking of cables and connectors.

The colored rings are available in eleven colors and can easily be clipped onto the connector body of an M12x1 round connector or onto the cable of an RJ45

Easy identification, the coloured rings can easily be clipped onto a connector body

The label carriers are slipped onto the cable and provide enough space for an individual marking.

connector or onto a flange with an overmolded cable.

ESCHA also offers four sizes of label carriers for applications where color coding is insufficient as more details have to be displayed on the cable.

The label carriers are slipped onto the cable and can thus be quickly and easily mounted.

Junction cables come standard with label carriers.

These two solutions will speed up installation as the connectors will be easily identifiable and will also help maintenance teams to identify the connector they are looking for. rodneyt@retauto.co.za

New flow indicator with rotor

I

ntroducing the rotating vane flow indicator model DAF, for application where visual flow indication without flow measurement is required.

A square housing with transparent front and back windows contains a rotating vane whose rotary motion, caused by the flowing medium, indicates presence of “flow”.

The DAF series may be installed in pipes from G 1/8 to G 1 ½ with the same housing.

Further versions are available with flange connection from DN 15 to DN 50. Flow ranges from

0.03…0.1 to 5…150 l/min can be obtained by changing the inlet port orifice.

The instruments can be installed in any position. Flow, however, must be in the direction indicated by the arrow. Four different material combinations allow an optimum instrument selection for a multitude of applications.

A housing made of complete plastic (Trogamid-T or polysulfone with stainless steel connections for aggressive media) provide a cost-effective flow indicator for pressures up

to 10 bar. The flow indicator DAF can also be supplied with a brass housing with Trogamid-T cover (or stainless steel housing with polysulfone cover) for pressures up to 16 bar.

The instruments can be used for temperatures up to 110 °C (polysulfone) or up to 60 °C (Trogamid-T).

The special connection supports enable optimum turning of the sight glass of this indicating unit for an optimum view even during operation. sales@instrotech.co.za

Intrinsically safe valve open/closed sensor for ATEX areas

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TEX approved equipment and devices are commonly used in hazardous working conditions.

They need to be extra strong and durable to withstand the elements that they will be exposed to. ifm has designed and developed its newest line in ATEX protection. ifm’s type IND inductive sensors are intrinsically safe and consist of two inductive sensors in a potted and robust housing with IP 67 protection rating. They are equipped with connection for solenoids.

Two sensors are built-in: one sensor provides a signal when the valve is open, the other when it is closed.

The solenoid connection is optionally a standardised M20 x 1 connector or an M12 connection. The terminal chamber is easy to open and close. Since the terminal block can be removed, no new wiring is required if the sensor is replaced. The units are approved to ATEX categories 1D/1G and 2G. The IND sensors provide easy access to the terminal chamber and feature a removable terminal block for easy wiring and a robust and resistant housing. They have a permanently legible lasered type label and fit directly on valve actuators. info.za@ifm.com

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18.2 Improve operational effectiveness with new electronic logbooks

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apturing log entries electronically minimises shift handover risk, improves task management, and facilitates collaboration. These logbooks enable operators to electronically document activity records to streamline shift changes, drive operator action, and accelerate decision-making.

A consistent approach to operator logs supports safety improvement efforts as well as audits and corrective action processes.

Shift handover can be a risky time for a plant; poor communication can quickly result in process upsets. Logbooks deliver a shift change dashboard that includes a shift summary and detailed information on assigned tasks. Operators can identify priorities for the new shift and access documentation of events

from the previous shift, ensuring quality, safety, and throughput are protected. The consolidated graphical view makes it easy to provide complete, accurate information to customers and auditors.

Automating task management ensures work is not overlooked or incomplete.

With the ability to schedule tasks now, later, or on a recurring basis, management can be confident that critical tasks are prioritized and important – but non-urgent – tasks like training, reviews, and routine maintenance are completed and documented.

Tasks are visible on the shift dashboard, so operators can

easily determine criticality and plan work. Information in paper logbooks is often hard to find. By moving to electronic logbooks, operators can establish an online knowledge base to speed up problem-solving and decisionmaking. Not only can operators search on text within the log entry, but they can also search on category, date/time span, related equipment, and a number of other attributes.

Operators have expertise critical to the success of a plant. They also have more responsibilities than ever before. Emerson is committed to delivering solutions that capture operator expertise while streamlining tracking and documentation for improved operation effectiveness.

Michael.Eksteen@Emerson.com

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18.2 FieldComm Group announces availability of Field Device Integration (FDI) specification and developer tools

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he FieldComm Group has announced that the FDI Cooperation, LLC’s Field Device Integration (FDI) specification, developer tools and common host components are now available for automation suppliers to develop products and host systems compatible with FDI. The FDI specification is publically released and made available through the FieldComm Group.

It was submitted to the International Electrotechnical Commission (IEC) for final approval in the international standardisation process and will be included in the emerging standard IEC 62769 which is expected to be approved Q1 2015.

The FieldComm Group, an organisation formed through the combining of two founding members of the FDI Cooperation, LLC—the Fieldbus Foundation and HART Communication Foundation—will deliver and support the FDI related products for FOUNDATION™ Fieldbus, HART® and PROFIBUS effective 16 February, 2015.

At the core of the FDI specification is the FDI Device Package that includes everything a host system needs to integrate an intelligent device.

With FDI, a single FDI

Device Package that can scale according to the complexities and requirements of each device makes it easier for automation suppliers to develop and integrate device information and configurations across a wide range of host systems and protocols.

With the release of the FDI specification, developer tools and host components, FieldComm Group now offers the support for the development of FDI based devices and host systems.

Developers may now implement and test FDI Device Packages using the FDI Integrated Development Environment (IDE), which will help device manufacturers create FDI Device Packages for FOUNDATION fieldbus, HART and PROFIBUS devices.

Host system manufacturers may also now implement FDI Host Components for host systems such as device management tools, asset management tools, or process automation systems.

FDI Host Components allow for rapid development and ensure FDI Device Packages behave consistently across different systems. FDI Host Components fully support the new unified EDD file format for FOUNDATION Fieldbus, HART and PROFIBUS devices as well as

existing FOUNDATION Fieldbus and HART EDDs to protect end user investments.

The FDI specification, developer tools and host components for FOUNDATION Fieldbus, HART and PROFIBUS will be available through the FieldComm Group at www. fieldcommgroup.org.

About FDI Cooperation, LLC The five major automation foundations, including the FDT Group, Fieldbus Foundation, HART Communication Foundation, Profibus & Profinet International, and OPC Foundation have developed a single common solution for Field Device Integration (FDI).

These foundations have combined their efforts to form a joint company named FDI Cooperation, LLC (a limited liability company under US law).

FDI Cooperation, LLC is headed by a “Board of Managers”, which is composed of the representatives of the involved organisations, as well as managers of global automation suppliers including ABB, Emerson, Endress+Hauser, Honeywell, Schneider Electric, Siemens and Yokogawa.

FDI Cooperation LLC marks an unprecedented level of cooperation among suppliers and foundations to achieve a single integration technology

for the benefit of end users. FDI’s mandate is to develop a single technology for the management of information that comes from all intelligent devices throughout all areas of the plant.

Learn more at the FDI Cooperation website at www.fdicooperation.com.

About the FieldComm Group The FieldComm Group is a global standards-based organisation consisting of leading process end users, manufacturers, universities and research organisations that work together to direct the development, incorporation and implementation of new and overlapping technologies and serves as the source for FDI technology.

The FieldComm Group’s mission is to develop, manage and promote global standards for integrating digital devices into automation system architectures while protecting processautomation investments in HART and FOUNDATION Fieldbus communication technologies.

Membership is open to anyone interested in the use of the technologies.

For more information, visit their web site at www. fieldcommgroup.org. sfielder@fieldcommgroup.org

Belt conveyor scale integrator

T

he Microtech 9101 belt conveyor scale integrator incorporates advanced electronic design for improved performance and serviceability. This fifth-generation integrator is flexible enough to accommodate specific weighing applications and improve process efficiency in a variety of industries while providing vital information for the management and operation of your business.

When combined with a Thermo Scientific conveyor belt scale weighbridge and a speed sensor, the Ramsey Microtech 9101 integrator can accurately monitor production output, control product load-out and keep track of inventory to help you manage your process effectively and efficiently.

Features: • State of the art LCD graphic display with four line display • Self-diagnostics, alpha numeric alarm messages

• Built-in USB for information upload and download • Multiple language interface • Improved communication capabilities • Audit trail • Automatic zero and span calibration • Automatic zero tracking • Alarms and failure detection • Available in panel and field- mount versions The Microtech 9000 series replaces the stalwart Microtech 2000 series. The Microtech 2000 series will be supported for the foreseeable future, in terms of spares availability however we recommend that endusers start adopting the new Microtech 9000 series.

The interface and menu structure is similar to the Microtech 2000 series, eliminating the need for retraining. michael.schlenther@thermo.co.za

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18.2 CMP Products opens office in South Africa to serve the African market

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MP Products, a division of British Engines Limited, a company registered in England, is expanding its international footprint. The company has established a branch in Midrand, South Africa to serve the African market. This branch provides additional support to the Company’s global network of established agents and distributors who CMP Cable Glands & Accessories represent CMP in all of the major countries around the world.

CMP CMP PRODUCTS

CMP Products is a leading designer, manufacturer, and supplier of cable glands, cable connectors, cable cleats and cable accessories for customers around the globe. The Company has for over 50 years cemented an international reputation for quality and reliability in various sectors of industry including Oil & Gas, Petrochemical, Pharmaceutical, Power Generation and Distribution, Mining and Transportation Infrastructure. Many of the Company’s innovative developments incorporate unique features and benefits which have evolved directly from its client’s needs and requirements. This is just one of the reasons for CMP Products being highly regarded as the specialist in the field of hazardous area cable gland design and manufacture.

CMP Products also offers a comprehensive range of cable cleats that support cables and conductors, retaining the mechanical load of the cable itself and reducing the mechanical stress placed on any cable termination.

CMP cable cleats are designed for use within heavy industrial applications and hazardous locations, as well as the arduous conditions and harsh environments encountered by operators in the railways, tunnels and underground, oil and gas and petrochemical industry sectors.

Cable cleats suit a variety of support structures including cable ladder, cable tray, basket, channel, masonry or concrete, and can be manufactured in a variety of materials to suit the environmental conditions they may be subjected to.

CMP Products is a quality assured company responsible for its own design and that operates a quality management system complying with the requirements of BS EN ISO 9001:2000.

In the offshore and onshore Oil and Gas sector, CMP has enjoyed considerable success in recent years, during a period of changing standards, both in respect of improved Safety and higher Quality expectations.

Attie.Booysen@cmp-products.com

The first of its kind – a level switch that can handle any environment ... ... temperatures from -196 to +450 °C, pressures from -1 to +160 bar, all liquids.

The new, patented drive of VEGASWING 66 as well as extremely temperature resistant materials make it possible.

▪ ▪ ▪ ▪ ▪ ▪

Point level switch and overfill protection device Liquid gas vessels, boilers and distillation columns Quick function test via keypress More reliable than capacitive probes and float switches Double security (through second line of defence) All approvals, and up to SIL3

www.vega.com/VEGASWING

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18.2 Third generation of factor 1 sensors

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nnouncing the release of the uprox3, the third generation of the range of uprox factor 1 sensors. Factor 1 sensors have the same switching distance

for all metals. The electronic platform of the uprox3 Series has been completely redeveloped, resulting in switching distances being increased by upto 50%.

Turck’s uprox3 Series currently offers the largest switching distances of all factor 1 sensors on the market.

The uprox3 Series, when mounted flush can attain a 3mm sensing distance in the M8 design, 6mm in the M12 design and 10mm in the M18 design. Due to the consistent development of its uprox technology, Turck has been able to achieve these larger switching distances without any compromises in terms of performance and mounting requirements. Turck has also managed to shorten the length of the previously most compact M8 to M18 designs.

The uprox3 sensors not only offer standard application reliability for demanding switching tasks, but also allow the possibility of completely new

applications. In a world first, Turck has also created a factor 1 sensor in the compact 4mm smooth barrel design and M5 design, both with a switching distance of 1mm, even when mounted flush.

Due to their inherent immunity to magnetic fields, the uprox3 Series sensors are suitable for use in many demanding industrial sectors such as welding applications.

Here, the new uprox3 Series once again offers especially robust PTFE coated sensors in M8, M12 and M18 designs.

Like their predecessors, all uprox3 sensors offer a high EMC stability and flexible mounting options right through to fully flush mounting in all metals, as well as precise switch points.

rodneyt@retauto.co.za

New 868-MHz wireless module with Trusted Wireless 2.0

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he Trusted Wireless 2.0 range of Radioline wireless communication products has been expanded with an 868-MHz wireless module. This module utilizes the 868-MHz frequency, which is publicly available and license-free in Europe, at a maximum transmission power of 500 mW, facilitating easy communication of I/O signals and serial data. This is particularly useful for outdoor applications such as in water and wastewater management or power supply

networks. The module represents a very simple and reliable solution for non-time-critical applications where signals need to be transmitted over long distances of up to 20 kilometers.

A special advantage of this wireless module stems from the adjustable data rate of its wireless interface in the range of 1.2 to 120 kbps, which increases the reception sensitivity. A low data rate can span a significantly longer distance than high data rates. As a result of the individual

adaptation, users can therefore make the optimum settings for their particular application and the required range.

The Radioline wireless system’s I/O mapping distributes signals across the system without requiring any prior programming.

All it takes is a turn of the knurled knob to assign the inputs and outputs. Each wireless module can be modularly expanded by up to 32 expansion modules. kevinp@phoenixcontact.co.za

Compact vortex flowmeter for low viscosity liquids

T

he compact KOBOLD Vortex flow meter Model DVZ is used for measuring and monitoring smaller and medium-sized flow of low viscosity, water-like liquids in pipes.

The device works using the vortex principle, making it virtually maintenance-free.

This involves the installation of a sharp-edged object (the vortex generator) in the flow duct. Vortices are created behind the object whose frequency is proportional to the velocity of flow of the liquid.

The flow volume can be determined with a high degree of accuracy by measuring the vortex frequency. The result is a very high linearity over the whole measuring range (0.5-4.5...10-100l/

min) with an accuracy of +2.5% of full scale.

The device can be fitted with switching, frequency or analogue outputs. There is also an optional compact electronics package that includes a digital display, and both a switching and analogue output. Dosing and metering electronics are currently being developed.

The DVZ vortex flow meter finds application in the following areas: • Monitoring the flow of low viscosity liquids • Measuring of aggressive, high-purity or salty solutions • Unsuitable for abrasive media or media containing a large proportion of fibers sales@instrotech.co.za

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18.2 Rugged submersible slurry pumps

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he KBS submersible slurry pumps are rugged in design and have the ability to pump both the corrosive and/or abrasive slurries found in the mining and process industries.

The pumps have a four-pole motor for an increased lifetime and agitator designed to handle tough applications.

Since water always flows to the path of least resistance, a pump without mechanical agitation will only pump the water, leaving the solids behind to accumulate around the pump intake, and eventually starving the pump by blocking the intake. Agitator pumps deliver kinetic energy (energy of motion) to slurry solids surrounding the pump intake, re-suspending them into a fluid state. These solids, which would have otherwise buried and starved the pump of liquid, are pulled into the pump and pushed on through the discharge keeping the intake clear and free of slurry accumulation.

The KBS pumps have a slim design with a top discharge enabling installation in smaller casings and they are suitable for bentonite mixed water in foundation works or muddy water in civil engineering works. They are also suited for applications in quarries, slurries and general pumping applications.

With a capacity up to 3.25m3/ min and heads up to 22 m, the pumps have an 80 mm to 150 mm discharge and operate in a 4 kW to 9 kW range. Meeting insulation class F, the submersible slurry pumps are suitable for use in water temperatures up to 40°C and in water depths up to 30 m. enquiries@raptech.co.za

See what it’s about

I

ntroducing the PLICSLED universal display module for all point level sensors. The module is compatible with all sensors in VEGA’s plics© family with relay output. With this new display module the switching status of a sensor can be read from a distance, even in strong sunlight. Since external wiring is unnecessary, the time needed for installation is reduced to a minimum. Power is

supplied via the relay electronics.

The second relay output is used to control the switching status display. Depending on the module version, the switching

status is displayed in the colour combination red-green or yellowgreen PLICSLED is installed directly inside the plics© sensor housing giving it protection from dust and water.

The display module can be ordered directly with the sensor or, alternatively, as a separate unit for retrofitting. chantal.groom@vega.com

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18.2 Reliable material flow with ultrasound

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n the beverages section of a supermarket, you will find rows of crates with bottles filled with water, soft drinks, or beer. The choice is not easy. Who would imagine that sensors play a key role when those bottles are filled?

Figure 1: Using ultrasonic sensors to count bottles monitors the material flow on a continuous basis.

The different colors of the glass or PET bottles and the colorful imprints or shiny labels call for the use of ultrasonic sensors, which work regardless of color and material.

While scanning ultrasonic sensors measure the time of flight of a sound packet and calculate the resulting distance, thru-beam ultrasonic sensors work with continuous sound and analyze the interruption. The result is extremely fast response times.

resistant film. In machine areas not affected by cleaning cycles, standard ultrasonic thru-beam sensors, such as the UBE1000-18GM40 Series, can be used. Since ultrasonic sensors from Pepperl+Fuchs can identify the most difficult materials, even transparent glass or plastic bottles are detected in a reliable manner. Detecting and counting the bottles at several places in the machine ensures continuous monitoring of the material flow. The entry and exit of the bottles to and from the filler is optimized, and missing bottles in the chain are reliably detected.

Reliable detection of bottles using ultrasonic thru-beam sensors is guaranteed in areas with high levels of water vapor.

Sheet Metal Off the Roll The material flow must not slow down in other applications either.

Take the example of a hydraulic punch, in which the sheet metal needs to be fed continuously. As a general rule, sheet metal is supplied in the form of large rolls. The sheet metal runs from the winding system to the press via a loop. A scanning ultrasonic sensor measures the loop sag to regulate the winding tension and reports when the material ends, so that the press is not damaged. Whether brass or steel sheet, oiled or coated—none of them will interfere with the ultrasonic sensor.

The sensor’s sound packets are reflected. The runtime is converted into distance and output in digital form as a switching signal, or in analog form via current or voltage.

Container Empty Container empty—a message that can result in an entire production line being shut down immediately.

System shutdown and loss of production—a horror for any production manager. Continuous measurement of the level of production or auxiliary materials is one traditional application of ultrasonic sensors.

The analog output of a cylindrical M30-design sensor continually provides the level, and a switching output reports—overfilling or container empty— to prevent something worse happening in the event of an emergency. The ultrasonic sensor is present no matter what media is in the tank: dough for a bakery, fruit juice for a filling system, or drilling emulsion as an auxiliary material in materials processing.

Figure 2: Ultrasonic thru-beam sensors are ideal for counting bottles at high speed Ultrasonic Sensors Ensure Reliable Material Flow In the food and beverages industry, speed and cleanliness set the tone. Short cycle times and minimum machine and/or system downtime are vital in this industry, and hygiene requirements must not be ignored either.

The strictest regulations and certifications are needed to produce high-quality end products. In bottling plants used in beverage production, incoming and outgoing bottles must be counted continuously, irrespective of material and liquid. To ensure the material flow, individual bottles are detected at the outlet of PET bottle blow molding machines and automatic bottle rinsers.

High Level of Chemical Resistance Passing bottles move too fast to be individually detected by the normal scanning of ultrasonic sensors because the bottles pass the sensor at high speed and often with just a very small gap between two bottles. Ultrasonic thru-beam sensors are perfect for the task of counting bottles. Ultrasound thru-beam sensors with increased chemical resistance are required, since these applications very often involve the use of hot steam and chemicals to clean machines. The IP protection category should therefore be a minimum of IP68/69K. The UBEC30018GM40 Series from Pepperl+Fuchs is ideal. With this sensor series, the transducer surface is specially protected and sealed by a chemically

Figure 3: The analog output of an ultrasonic sensor provides the level in the tank irrespective of the medium.

The Pulse of Automation Ultrasonic sensors in pulse mode or continuous thru-beam mode help to ensure and control the material flow in a reliable manner across a wide variety of applications. Ultrasonic sensors are ideal for these applications due to their rugged yet precise measuring method. Simple parameterization - if the application requires it - links measuring ranges from a few centimeters up to 10 m - and ultrasonic sensors rise from being just a problem solver to the sensor for all applications.

It is already generally well-known that ultrasonic sensors are used as a parking assist for cars. In the field of factory automation, these sensors are an often underestimated technology for noncontact object detection. mbracco@za.pepperl-fuchs.com

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18.2 New generation of hazardous area remote terminals

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he new MTL GECMA RT remote operating terminal enables plant managers to reduce operation costs, optimise productivity and increase plant safety.

The new terminal has a unique modular design and is a next generation remote terminal which features state-of-the-art technology to offer unparalleled levels of safety, making it ideal for use in hazardous EX zone areas in chemical, pharmaceutical, refinery and oil and gas industries worldwide.

The MTL GECMA RT consists of five electronic modules; the display unit, power supply, communications modules, keyboard and mouse.

The terminal’s modularity means upgrades to existing installations are quick and easy, which can save time, and minimise costly maintenance and downtime.

Traditionally, the whole unit would have to be dismantled off site, but now individual parts can be replaced simply on site, increasing plant availability.

Of vital importance, the modules are individually approved to global hazardous certification for Zone 1 environments.

This offers safe handling on site and independent of the housing, and guarantees high reliability - worldwide.The MTL GECMA RT features a couple of unique safety functions.

First is a unique intrinsically

safe cable for secure data transmission.

Users can specify an Ethernet or fibre optic cable between the control room and remote terminal, with no need for additional external cable protection.

This provides a saving of approximately 50% of wiring cost.

Secondly, the terminal features a unique visual alarm to immediately warn users in the event of a process failure.

The alarm visualization system checks the correct data transmission to the display in real time and alerts users by way of a flashing red icon, enabling them to act straight away to rectify the problem.

The MTL GECMA RT is the only remote operating terminal of its kind on the market to feature a visual alarm – other terminal screens typically freeze if there is a process fault – and it is expected to help plant managers reduce downtime and associated operating costs.

Available from stock and pre-tested, the MTL GECMA RT operating terminals are designed to enhance visualization within plant processes using displays ranging from 19 to 24 inches, with full HD versions offered in 22 and 24 inches.

Displays are of the highest industrial quality and to ensure the best readability, the terminal incorporates optical bonding and LED-backlit technology resulting in a high resolution image in a low power display.

The USB interface futureproofs investment and allows easy expansion for additional connected devices, such as scanners or printers.

MTL GECMA RT also supports WLAN and Bluetooth.

MTL GECMA RT is available with a large range of cost effective specialist housing options.

The flexibility of the design allows engineers to customise the housing to suit their application and the slimline stainless steel housing can be mounted to the floor, ceiling or other suitable stable object as required. sales@extech.co.za

For the highest level of quality

Searching for precise and efficient level measurement? No problem with KROHNE. KROHNE is a pioneer of FMCW radar technology for the process industry, inspiring our customers with innovative and reliable level measurement solutions. Many of the products, which are now considered industrial standards, were developed by us in cooperation with our customers.

For continuous level measurement we offer in addition to the FMCW radar also TDR ultrasonic and mechanical measuring instruments. A complete series of level switches for liquids and solutions for hygienic applications round out the KROHNE level portfolio.

KROHNE devices are characterised by their high application certainty, even in difficult applications such as foam, interfaces or moving surfaces.

KROHNE – Level measurement is our world.

KROHNE South Africa 8 Bushbuck Close Corporate Park South Randtjiespark, Midrand Tel.: +27 113141391 Fax: +27 113141681 Cell: +27 825563934 John Alexander j.alexander@krohne.com www.za.krohne.com

(open/closed) to be safely monitored over even greater distances.

Constant innovation means that inductive sensor technology is infiltrating

Constant innovation means that inductive sensor technology is infiltrating

more and more applications that had previously been reserved for

20

more and more applications that had previously been reserved for

mechanical and magnetic contacts, paving the way for similar industry

solutions inmechanical the future. and magnetic contacts, paving the way for similar industry

solutions in the future.

18.2

Weathering the storm – inductive dual sensor system

T

he F31K2 inductive dual sensor is the newest product for valve position signaling on valve actuators and rounds off the “open solutions” portfolio.

There are only two basic elements to the concept: the highly impermeable, robust sensor and the actuator.

Standardized mounting dimensions and hole spacing mean that both components can simply be mounted “openly” on the valve actuator without any additional mounting accessories, hence the term “open solution.”

F31K2 dual sensor with actuator and display on a valve actuator All weather conditions The F31K2 is ideal for open solution applications based outdoors.

Dual sensor with actuator and display on a valve actuator F31K2 dual sensor with actuator and display on a valve actuator The sensor series is designed for outdoor applications where compromising is out of the question.

The housing materials offer a high level of impermeability, temperature resistance, corrosion resistance, and UV protection. With a large terminal compartment and a plug-in terminal block, even cables with large diameters can be easily used in “inconvenient” mounting locations.

The F31K2 is designed for the international market. As the requirements in Europe, Asia, and America can vary significantly, a choice of different housing materials (high-quality, robust plastic; metal) is available.

Housings are available with different connection options via cable PR-2014-2468FA-ENG-WeatheringtheStorm-dualsensorF31K2_HMI_HMI glands or conduits with metric dimensions or inch threads and a very The weatherproof and watertight solution high tightening torque.

The temperature range of -40 °C … +75 °C and IP66/67/69K ingress F31K2—the weatherproof and watertight solution protection ratings offer a high level of impermeability and long-term durability and cover the majority of applications.

The target group for this sensor is customers with outdoor F31K2—the weatherproof and watertight solution applications and those with onshore and offshore installations. The Pepperl+Fuchs actuator concept, proven over many years, is also featured in this series of sensors.

To date, no other sensor system for valve position signaling offers such a variety of shaft heights and diameters without additional PR-2014-2468FA-ENG-WeatheringtheStorm-dualsensorF31K2_HMI_HMI mounting accessories.

A new puck system has also been developed, which allows even better long-distance visibility.

This system allows valve positions (open/closed) to be safely PR-2014-2468FA-ENG-WeatheringtheStorm-dualsensorF31K2_HMI_HMI monitored over even greater distances.

High-specification Zone 1 smartphone Constant innovation means that inductive sensor technology is infiltrating more and more applications that had previously been reserved for mechanical and magnetic contacts, paving the way for The new, intrinsically safe, Extronics Rough Pro is a high similar industry solutions in the future. specification, extremely rugged smartphone with a large, mbracco@za.pepperl-fuchs.com

crystal-clear 4.5" gorilla glass screen. The unit is ideal Two inductive dual sensors from the F31K2 Series being used to signal valve for "Smart Worker" solutionsfrom in the most of Two inductive dualactuators sensors theextreme F31K2 Series being used to signal environments. positions on pneumatic

valve positions on pneumatic actuators Key features

High-specification Zone 1 smartphone mbracco@za.pepperl-fuchs.com

Android OS - Extronics Rough Pro smartphones can run numerous applications.

High-specification Zone 1 smartphone

T

he new, intrinsically safe, Extronics Rough Pro is a high specification, extremely rugged smartphone with a large, crystal-clear 4.5” gorilla glass screen.

The unit is ideal for “Smart Worker” solutions in the most extreme of environments.

Key features • Android OS - Extronics Rough Pro smartphones can run numerous applications.

• Screen Quality - The large 4.5” screen is easily readable - even in direct sunlight.

• 8 Megapixel Camera - High resolution photographs and video streaming.

• Highly Connected - Dual SIM quad band, Bluetooth, Wi-Fi and mobile network features.

• Rugged & Shockproof - High build quality and

Page 2

Screen Quality - The large 4.5" screen is easily readable

- evenharshest in direct sunlight.

MIL-STD 810G certified. Ideal for the environments.

The new, intrinsically safe, Extronics Rough Pro Camera is a high- High resolution photographs and 8 Megapixel extremely rugged smartphone with a large, streaming.

• Waterproof -specification, Rated as bevideo submerged crystal-clear 4.5"IP68 gorilla can glass screen.

The unit is ideal for "Smart Worker" solutions in theHighly most extreme of - Dual SIM quad band, Bluetooth, WiConnected in water for 40 minutes. environments.

Fi and mobile network features.

• Fully Featured - With GPS, accelerometer, Gyro Key features Rugged & Shockproof - High build quality and MIL-STD and compass, The Extronics Rough Pro is the 810G certified. Ideal for the harshest environments.

OS - Extronics Pro smartphones ideal tool forAndroid worker safetyRough solutions such can asrun numerous applications.

Waterproof - Rated as IP68 can be submerged in water location tracking and man-down. for 40 minutes.

- The large 4.5" screen is easily readable The RoughScreen ProinQuality is the latest product from - even direct sunlight.

Fully Featured - With GPS, accelerometer, Gyro and compass, The Extronics Rough Pro is the ideal tool for Extronics designed to help companies operate worker safety solutions 8 Megapixel Camera - High resolution photographs and such as location tracking and with high efficiency in hazardous areas. video streaming. man-down.

With ATEXHighly & Connected IECEx Zone 1 certifi cation, - Dual SIM quad band, Bluetooth, Wi-latest product from Extronics The Rough Pro is the and mobile network features. designed to help companies operate with high efficiency the Extronics FiRough Pro has the features and in hazardous areas. pedigree needed to &succeed.

Rugged Shockproof - High build quality and MIL-STD 810G certified. Ideal for the harshest environments.

With ATEX & IECEx Zone 1 certification, the Extronics Rough Pro has the features and pedigree needed to

succeed.

Waterproof - Rated as IP68 can be submerged in water sales@extech.co.za for 40 minutes.

sales@extech.co.za Fully Featured - With GPS, accelerometer, Gyro and compass, The Extronics Rough Pro is the ideal tool for worker safety solutions such as location tracking and man-down.

21

18.2 VEGA Instruments offers promising drama student a scholarship to complete her studies.

Mokokobale Makgopa

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hen Mokokobale Diana Makgopa’s Professor of Drama at UCT send out an urgent appeal for a sponsorship to allow her to complete her studies, little did he expect to hear good news from a company selling pressure and level instruments.

But VEGA Instruments has a social responsibility track record for giving deserving young people a chance to succeed in life, and

when MD John Groom received Professor Fleishman’s motivation letter it was hard to ignore. The result was a R60 000 sponsorship towards Mokokobale’s student fees, allowing her to complete her studies at UCT. Mokokobale has completed two years of the BA Theatre & Performance Degree within the Drama Department and is on course to graduate at the end of 2016.

The BA Theatre & Performance Degree is a four-year, honours equivalent programme.

According to Professor Fleishman, “Mokokobale has grown, from a slow beginning, to be considered one of our strongest and most admired students. Mokokobale has overcome more obstacles than most in fulfilling her dream of studying Theatre & Performance at UCT. Coming from the Limpopo

Province, Mokokobale achieved an entrance scholarship from the Humanities Faculty in her first year and through consistent and dedicated hard work achieved the Dean’s Merit List in 2014. Her academic achievements continue to grow and her passion for her studies and chosen field is

Makokobale in the production of Mbuzeni

unwavering, despite the financial difficulties that her family faces”.

VEGA Instruments’ financial intervention has allowed this promising your student to focus on her studies and not to worry about further student debt. Who knows, we might one day see her nominated for the Oscars?

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18.2 Innovative solution for level measurement in pressurised or vacuum vessels

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he Deltabar FMD71 and FMD72 electronic differential pressure, the latest instrument family for level measurement, combines all of the strengths of the brand: uncompromising quality, the highest degree of reliability and safety for users and processes as well as groundbreaking cost-efficiency across the entire life cycle.

The design and the electronic architecture of the system eliminate the typical problems of impulse line and capillary systems.

The level, volume or mass of liquids in pressurized tanks or vacuum tanks is commonly determined by differential pressure. The problems most frequently mentioned in conventional differential pressure measurements with impulse lines or oil-filled capillaries are unreliable measured values due to temperature impact, clogging,

icing, leaks or condensate.

The new electronic differential pressure system, Deltabar FMD71 and FMD72, eliminates these problems. The system not only provides precise measured values but also facilitates reliable and safe process control – and all of this with the lowest operating costs. Production downtimes due to unexpected maintenance requirements are now a matter of the past.

The right sensor technology increases reliability, safety and cost efficiency.

Every application has its specific requirements, be it vacuum, abrasion, acid, condensate, steam or temperature changes. The electronic dp system is available with Ceraphire ceramic cells – Deltabar FMD71 – as well as with silicon metal cells – Deltabar FMD72. info@za.endress.com

New ultrasonic flowmeter for superheated steam

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he OPTISONIC 8300 is a dedicated ultrasonic flowmeter for the measurement of superheated steam. The 2-beam flowmeter stands out with a measuring accuracy of 1 %, high repeatability, and a large dynamic measuring range. Typical applications include boiler and plant efficiency monitoring in (power) plants, energy balancing or intercompany steam billing.

As downtime of steam pipes is very costly and must be avoided, OPTISONIC 8300 was built for long term use: it features a full bore flow sensor without moving parts or obstructions, and an overall sturdy and robust construction with no cables or sensitive parts exposed.

Therefore, it can uphold its measuring accuracy without maintenance or subsequent calibration for up to 20 years, while keeping operating costs at a minimum. If verification

ifm electronic

➢ 0861 436 772 www.ifm.com/za

of the measuring accuracy should become necessary, it can be provided by using the flowmeter diagnostics, without removing the flowmeter.

With nominal sizes ranging from DN 100...1000 / 4…40”, OPTISONIC 8300 is particularly suited to high flow rates.

Pressure rating up to 200 bar / 3625 psi and temperature rating up to 540 °C / 1004 °F are available, higher requirements on request.

With temperature and pressure sensors connected to the device, the integrated flow computer can calculate steam mass flow.

OPTISONIC 8300 adds to KROHNEs portfolio of ultrasonic process and custody transfer meters for liquids and gases, ranging from compressed air to liquid natural gas (LNG). salesza@krohne.com

HONEYWELL

➢ 011 805 1201 Boni.Magudulela@honeywell.com

OPTISONIC 8300 2-beam ultrasonic flowmeter for high flow rates of superheated steam

RET AUTOMATION CONTROLS

➢ 011 453 2468 www.retautomation.com

BECKHOFF AUTOMATION

➢ 011 795 2898 www.beckhoff.co.za

23

18.2 Coriolis flow in efficient two-wire technology for higher safety and lower cost in the chemical industry.

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rocess monitoring is becoming more demanding and the need for maximum product quality is steadily increasing. he new generation of Proline flowmeters is based on a uniform device concept.

This means time and cost savings, as well as maximum safety over the entire plant life cycle.

In the chemical process industry, Coriolis flowmeters have been used for decades with great success. This is in no way astonishing, because this measurement technology has unique advantages in comparison to other methods: • Independent of physical fluid properties

such as conductivity, pressure, temperature, density or viscosity • One-of-a-kind multi-functionality – simultaneous measurement of mass flow, volume flow, density and temperature • Maintenance-free devices without moving parts • No inlet and outlet runs required • Operable flow range of up to 1000:1 • Insensitive to external process influences such as pipe vibrations • High field accuracy, even with greatly fluctuating process and ambient conditions Proline is a proven and uniform product concept, designed to do the same things the same way, thereby increasing the safety and efficiency of your operations.

The Human Machine Interface (HMI) and subsequent device set-up and programming are user-friendly through and through.

This ensures that your process can be securely controlled with confidence and can be integrated seamlessly into your plant asset management, providing reliable information for optimizing production and business processes. The Promass 200 has

been developed for SIL2/3 applications and has internationally recognised Ex approval including the local South African requirements.

Round-the-clock operational safety and plant availability are particularly important in the chemical and petrochemical industry and the Promass 200 consistently ensures this higher safety and thereby enabling lower operating costs. In addition, plants have to be operated as cost-effectively as possible over the years so as to attain high performance and availability.

The complexity involved, whether in the process or in utilities, can only be managed by uniform and standardized field instrumentation. Promass 200 is the perfect solution for exactly such areas of application.

As a true two-wire device, the Promass 200 can be integrated into existing plant systems to provide the following: • High operational safety in Ex areas due to the intrinsically safe design (Ex ia) • Reduce cost for installation and wiring • Seamless system integration and wiring.

• Common installation practice. info@za.endress.com

Latest level transmitter increases capabilities of ‘Smart’ field products

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nnouncing the launch of the SmartLine® Guided Wave Radar Level transmitter, the latest addition to HPS’s SmartLine® industrial transmitter family.

The new device can measure the level and volume of liquids inside processing tanks up to 160 feet in height. The high performance SmartLine Guided Wave Radar Level transmitter features industry leading specifications as well as an advanced level of user experience with the introduction of the Application Validation Tool. This online tool allows customers to input technical data about their specific process tank and to validate that the correct level transmitter application is delivered to the site ready to install out of the box. The new SmartLine level transmitter leverages the same proven platform, innovative modular design and ease of use as the pressure and temperature transmitters. This helps facilities manage cost by reducing inventory, speeding start-up and, with Honeywell’s Application Validation Tool, operators can have complete confidence that the level transmitter

ordered will be the correct one for the tank application.The new level transmitter features a choice of a basic alphanumeric display or an advanced graphics display. The advanced graphics display, capable of showing process data in graphical formats and communicating messages from the control room, also offers multiple languages and full integration with Honeywell’s flagship Experion® process control system.Field instruments are used throughout industrial plants to measure and transmit critical data points from throughout the processes to the control room. Large industrial complexes, such as those for refining crude oil or producing chemical products, can employ thousands of these devices within their manufacturing processes.

The SmartLine instrument line also includes: SmartLine Temperature transmitters measure temperature accurately and reliably in industrial processes in tough and noisy environments, converting low level signals from temperature sensors to analog and digital output signal SmartLine Pressure transmitters measure absolute pressure, gauge pressure, differential pressure, and flanged and remote seal transmitters. Refineries, chemical and pharmaceutical plants and paper mills around the globe rely on theses transmitters for accurate and consistent pressure measurement.

Honeywell introduced

the smarter field device concept with its SmartLine Pressure transmitter, the industry’s first modular and most reliable transmitter delivering value across the entire plant lifecycle. Setting a standard for ease of use and total performance in harsh and noisy process environments, the SmartLine family also offers lower total cost of ownership, from reducing initial purchasing costs, providing flexibility for post start-up modifications, reducing maintenance and inventory costs along with high accuracy and stability.

SmartLine transmitters integrate with all control systems, however when integrated with Honeywell’s Experion® PKS, operators benefit from these unique advantages: • Extended diagnostics – assess the health of critical field assets • Maintenance status display – confirm the transmitter is in the right mode before maintenance can be performed • Transmitter messaging – allows the operator to send messages to the transmitters advanced display • Tamper alert – provides ability to detect unauthorized access of transmitters in remote locations such as pipelines and wellheads.

Discover Honeywell at Booth B1 at the Africa Automation fair 2015 - The Dome, North Riding, Johannesburg. boni.magudulela@honeywell.com

24

18.2 Level measurement in foaming media

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xact level measurement in heavily foaming media – no problem for the new LFP Inox level sensor. The measuring principle of guided radar provides for utmost reliability; the hygiene-

respectively. In this scenario, many level measurement systems reach their limit: Capacitive systems and conductivity probes do not submit reliable measured values due to product buildups;

level design of the sensor opens up a great variety of possible uses in the food, beverage, and pharmaceutical industries.

Particularly in dairies and breweries, one has to anticipate heavy foaming all the way to the generation of wet, compact foams in the course or conveying, mixing, and bottling milk or beer,

in general, float switches do not meet hygienic requirements concerning cleaning capability and sterilisation. The LFP Inox is the ideal solution for such applications.

Reliable foam suppression and certified hygienic design Thanks to the measurement principle of time domain

reflectometry (TDR), i.e. of guided radar, the LFP Inox is capable of differentiating reliably between liquid media and foams or built-up deposits. Based on the maximum measuring range of 4,000 mm, the CIP- and SIP-resistant measurement probe can be cut as desired all the way down to 200 mm. It is made of FDA-compliant, food grade stainless steel that features a surface roughness of Ra = 0.8 μm. This facilitates residue-free cleaning, minimises the possibility of buildups, thus preventing hotbeds for bacteria and other micro-organisms.

Just the same applies to the changeable, hygienic process connections of the LFP Inox. The level sensor has been certified by the EHEDG (European Hygienic Engineering & Design Group) and also meets the 3-A hygiene certificate of the US food industry.

Permits flexible automation The LFP Inox combines continuous level measurement and point level detection. The

Touch sensor – start, stop and acknowledge

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he KT capacitive touch sensors can be used, for example, as a start and stop function on machines or as an enable switch for opening and closing gates. Compared to mechanical switches the sensors operate without wear.

Dynamic touch sensors can detect an approaching human hand and suppress interference such as water, layers of ice or foreign bodies to a large extent. Even a gloved hand will still trigger them.

Static touch sensors detect hands and objects through glass for as long as the sensing face is covered which provides, for example, protection against vandalism.

With the latching operating principle it is possible to switch the sensor on by touching briefly and to switch it off again by touching briefly.

display, a switchable 4 – 20 mA and 0 – 10 V analog output, respectively, IO-Link for individual parameterisation, diagnosis and visualisation options, as well as two transistor switching outputs are accommodated in the compact sensor housing that meets the requirements of both the IP 67 and IP 69K enclosure ratings. Simple commissioning, maintenance-free operation, and a high degree of independence regarding the properties of the medium to be measured, which means that the sensor requires no recalcitration, result in very substantial savings in time and costs. Consequently, in technical and economical terms, the LFP Inox is the ideal solution for level measurement in buffering containers of filling plants, for monitoring levels in rinsers and CIP facilities, and in cosmetic and pharmaceutical mixers. duncan.venter@ sickautomation.co.za

Applicationoriented and always ready for new tasks

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The housing is resistant to oils and it is also impact and scratch resistant. Symbols on the sensing face can be selected separately.

The sensor offers the protection rating IP 69K and a wide temperature range from -40 to 85 °C. LEDs for optical feedback signal that the sensor has been activated. The green LEDs can be controlled separately and, for example, be used to indicate the status of plant and machinery.The sensor can be installed in all housings with a 22.5 mm Ø. Installation alignment of the sensor is not necessary since the clip showing the symbol for the sensing face is snapped in as the last step. Wiring is done via the tried-and-tested 3- or 4-wire technology.

he H250 M40 is purely mechanical in design and this forms the basis for its flexible uses. Additional electronic modules can be added or replaced at any time, making it possible to scale the functionality at will. This way the device adapts easily to any changing requirements.

Anything is possible, from analogue flow measurement without auxiliary power to digital integration into a fieldbus system.

Simply screw off the cover, insert the module until it clicks, screw the cover back on and that‘s it. There is no need for tools or to interrupt the process for the functionality to be scaled at will. It is just as easy to replace the measuring scale in the event of a change in application.

info.za@ifm.com

i.thushini@krohne.com

25

18.2 A competitive edge for the furniture industry

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he theme of automation has been one of the core issues in the furniture industry for years. In the context of Industry 4.0, it has become the focus of Ligna 2015, the world’s leading trade fair of the wood and furniture industry: the notions of “smart factory” and “networked production” refer to intelligent, networked production systems that provide innovative solutions for the entire value chain in the furniture industry.

PC-based control provides the basic technology for production concepts that are ready for Industry 4.0.

In the furniture industry, customer demands in terms of colours, shapes, haptic properties and materials are becoming more and more individual. This presents major challenges for manufacturers, particularly in high-wage countries: the growing product variety, small batch sizes and short lead times have to be managed competitively, i.e. at costs that are comparable to mass production and with rapid availability, while at the same time focusing on optimised resource and energy efficiency.

The solution is provided by networked, intelligent production systems with a high degree of automation, i.e. a control concept that leverages the increasing convergence of information and automation technology and enables seamless communication.

Industry 4.0 increases the flexibility, efficiency, and sustainability of production through the networking of products, production resources and facilities along the global

value creation chain. Here, PCbased control technology from

and integrated engineering throughout the whole product

Beckhoff is a key enabler: The PC as a control platform with open communication interfaces provides the prerequisites for an optimal implementation of the vertical and horizontal integration required for Industry 4.0 and the networked production.

With PC-based control it is already possible to seamlessly integrate production systems and modules into existing and new production systems, and to communicate with these and with higher-level production planning and control levels on secure channels. In this way, it is possible to adapt ongoing operations to changes in order planning or the production process.

TwinCAT 3 automation software provides the required modularity, object orientation

lifecycle.

• PC-based control delivers the prerequisites for implementing Industry 4.0 concepts: • Integrated networking via standardised interfaces from the sensor to the ERP/MES level • M2M communication via the Internet of Things • Process safety, realised by means of integrated measurement technology and Condition Monitoring • Sustainable production through power monitoring and power management • Integration of robotics and new drive technologies • Integration of safety and security • Integrated engineering • Reduced commissioning times through real-time simulation

• Worldwide remote production maintenance ScAut research project focuses on enhancing the intelligence of technical systems The research project “ScAut” is part of the Industry 4.0 concept. It explores the integration of engineering and scientific knowledge from various disciplines into automation to enhance the intelligence of technical systems.

ScAut is one of more than 45 research projects of the technology network “it’s OWL” (Intelligent Technical Systems OstWestfalenLippe). ScAut was awarded Leading-Edge Cluster status by the German Federal Ministry of Education and Research (BMBF) in 2012 and is the first major Industry 4.0 project. The aim is to create a Scientific Automation platform for the development and operation of intelligent, self-optimising machines and equipment. Smart, reusable automation solutions are provided as software modules or intelligent Bus Terminals.

These developments are intended to enable production facilities to automatically anticipate wear, reduce emissions and environmental impacts, optimise energy consumption and avoid production faults.

As a result, rejects, lead times and harmful emissions are reduced while the service life of tools and the sustainability of systems are increased, without significant increases in the cost of the automation technology. kennethm@beckhoff.co.za

Flow meters for very low flows

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odel KSV flow meters and switches are for very low flows with and without control valves – so even the lowest possible liquid or gas flow rates can be measured. Specifically for liquids or air, the KSV operates on the suspended float principle. The direction of flow is from bottom to top, and the installation position is vertical. The indication point is the upper edge of the ball. The device has been designed as a simple, and thus economical measuring system. The optional

needle valve allows economical control and the device has been designed for panel mounting.

Kobold’s KSV flow meters are acid and caustic-proof, made of polycarbonate and brass or polysulfone and stainless steel materials. They are highly suited for advanced applications in medical technology because these units are sterilizable, operating at temperatures of +120°C. They can also be used for a wide range of applications in the analytical instrumentation

field, within production and environmental monitoring, as well as in laboratory measurement and monitoring technology.

They are shock resistant, small (panel cut-out 93 + 0.5mm x 23 +0.5mm), lightweight and very simple to install.

Available measuring ranges include: • Water 0.25-1.5…10-80l/h • Air 20-80 Nl/h…0.5 – 2-5Nm3/h • Accuracy: + 6% of full scale sales@instrotech.co.za

26

18.2 Potentiometric measuring technique for viscous, sticky media

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he KOBOLD LNP continuous level probe is a potentiometric measuring technique for viscous, sticky media. This level probe is accurate and reliable even in viscous and sticky media.

The instruments working according to the potentiometric measuring principle can be used for continuous level measurement even in low conductivity liquids.

The Kobold level probes LNP serve for continuous level

measurement of liquids with negligible conductivity. Levels in vessels containing viscous, pasty or very sticky media can be measured accurately with this new potentiometric method of measurement. It is most suitable for use in small vessels and for measuring fill heights greater than 200 mm.

The probe consists of a head mounted transmitter: this means that a 4…20 mA analogue output signal, that is electrically isolated from the supply voltage, is available.

The probe can be mounted from the top or bottom. The output signal is automatically output positionally accurate.

Single stem probes can be used in metallic vessels where the tank wall is parallel to the stem.

The devices with the KOBOLD weld-in sleeve LZE form a hygienic measuring point which is cavity free and is ideally suited for CIP/ SIP cleaning.

The Measuring Principles A defined potentiometer in the form of a stem is immersed in the medium.

Thus a measuring bridge is created to the side of the tank or to the ground stem.

The resistance of the measuring bridge changes in proportion to the level. In opposition with the classic potentiometer, the contact with the liquid is not at a certain point,

Equivalent circuit diagram for measuring principle

but along the entire length of the immersed probe. See the equivalent circuit diagram for measuring technique.

In the electrical equivalent circuit diagram, the liquid is represented by two equivalent resistors, RF1 and RF2, of equal size. They divide the measuring signal exactly by two –an effect which makes it mathematically easy to correct.

Kobold level probes LNP: • Suited for viscous, pasty very sticky media

• Stem length: 200…2000mm • Accuracy: ±1% of stem length • P max: 10 bar; t max: 5°C (shorttime 150 °C) • Process connection: G 1, 1 “ NPT hygienic mounting (EHEDG) with installation system LZE • Food compatible materials stainless steel and PEEK • Analogue output: 4…20 mA • 8-digit LED-chain trend display • 7-point linearity function for volume calibration sales@instrotech.co.za

New titanium level probe for use in salt or chlorine water

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pecifically designed for level measurement in maritime salt water or water that contains chlorine such as swimming pools, the new Jumo MAERA S29 SW titanium level probe is highly resistant and can also be used in potentially explosive areas.

The probe is available for relative and absolute pressures from 100 mbar to 10 bar.

The chemically high-resistant titanium design and the intrinsically safe ATEX approval allow the probe to be used in difficult environmental conditions.

An example is continuous level measurement in ballast water tanks to ensure a ship’s ideal depth, or for anti-heeling systems in ships. Another specific application is in splash chlorine water containers. In addition, the probe is ideal for measurement in tough and highly viscous media such as heavy oil.

The level probe has a medium-separated, piezo-resistive measuring system with front-

flush membrane, providing outstanding moisture and vibration protection. A two-wire reverse polarity protection mechanism which protects the measuring instrument against damage ensures maximum safety in the event of a faulty startup.

The design includes a removable protective cap giving users the option of a front-flush variant with G½” external thread. The temperature of the medium can lie between 0 and 50º C, although lower temperatures are possible depending on the medium.In combination with the extensive range of accessories that are available from Jumo through local agent, Randburg-based ASSTech, allows the creation of an integrated measuring station solution with an unbeatable priceperformance ratio. info@asstech.co.za

27

18.2 Enhanced integrated distributed control system

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anufacturers today need a high degree of certainty and confidence to achieve timely production, and flexibility to make changes in product and material specifications.

This enables them to effectively respond to intense global competition and major market shifts.

CENTUM® VP R6.01 has been released, an enhanced version of the company’s flagship integrated distributed control system, this

morning. R6.01 marks the first step in the development of an all-new CENTUM VP that will play a central role in the VigilantPlant® strategy for the Industrial Automation business.

The adaptive evolution of the new CENTUM VP focuses on addressing customers’ needs to keep up with the fast pace of change in the business landscape and technology while delivering maximum return on assets and the lowest total cost of ownership.

This first R6-level release of the CENTUM VP system represents much more than conventional functional improvements. R6 brings together smart engineering, advanced operation, system agility, and sustainable plant. With R6, plant operators can be assured of an optimum engineering environment that spans the entire plant lifecycle, from plant design and the engineering and installation of systems and devices to the start-up of production, maintenance, and renovation.

In addition, it is designed to meet the most stringent industry requirements for safe and reliable plant operations and environmental protection.

R6.01 features an exciting expansion of Yokogawa’s lineup of I/O devices and introduces crucial new control system components. Combined with an intuitive engineering environment, it dramatically

reduces the time required to configure and install a control system.

The new features include: 1. N-IO (Network-IO): A field I/O device with a versatile I/O module that can handle multiple types of I/O signals. The N-IO, a new CENTUM VP field I/O device, fulfills the functions of universal I/O and a signal conditioner, enabling configurable software and flexible I/O assignment. It has an I/O module that accommodates multiple I/O signal types, accepts up to 16 I/O points, and allows specification of an individual signal type for each point.

2. FieldMateTM Validator: A software tool that is used with N-IO devices to check field device wiring and verify that the device operates correctly.

3. Automation Design Suite (AD Suite): A first-of-its-kind integrated engineering environment that goes beyond traditional DCS engineering functionality. AD Suite is an integrated platform that ingenuously facilitates project execution, system integration, and site execution, bringing certainty and confidence through all project phases and the start-up, operation, maintenance, expansion/upgrade, and extension stages of the plant lifecycle.

Christie.cronje@za.yokogawa.com

Fan, compressor and pump motor protection

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he KD and KE low voltage electronic motor protection relays find widespread usage in all industries where comprehensive motor protection is a must. These relays are ideal when communications options are not required but excellent all round protection and motor management are nonetheless critical. From a safety view point the added earth insulation lockout, as well earth leakage protection will be a positive attribute.The distinguishing benefits of these products include excellent earth leakage protection before the motor is started and while running, and power factor measurements for data leading to the improvement of motor efficiency. The relays provide enhanced short circuit protection relating to power factor measurement, as well as statistical motor information pertaining to starts, trips, event records etc. The motor information can be downloaded.

KD and KE relays feature use-selectable thermal curves, a full house of protection features including start per hour limitations and the possibility to communicate with the relay without opening the cubicle door via infra-red. The attached integrated current transformer allows direct measurements from 0.1 to 50 Amps while the current range may be extended using interposing CTs. The relays are easy to setup via a man-to-machine interface (MMI) unit with infrared link or via a computer with free setup software. sales@newelec.co.za

HONEYWELL

➢ 011 805 1201 Boni.Magudulela@honeywell.com

RET AUTOMATION CONTROLS

➢ 011 453 2468 www.retautomation.com

BECKHOFF AUTOMATION

➢ 011 795 2898 www.beckhoff.co.za

ifm electronic

➢ 0861 436 772 www.ifm.com/za

28

18.2 Frost & Sullivan recognizes Setpoint’s condition monitoring solution

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n a market where the online condition monitoring trend is gaining prominence, and diagnostics and predictive maintenance strategies are becoming more important in understanding the causes for machine failure, Frost & Sullivan has awarded Setpoint with the 2014 Global Frost & Sullivan Award for Customer Value Leadership. Companies that are able to effectively deliver and communicate the value and cost benefits of such hardware and software condition monitoring solutions are expected to be highly successful in this market.

The Setpoint story began in 2010 when Metrix Instrument Company embarked on efforts to expand into the API 670 monitoring market. Initially, Metrix had focused primarily on device-level offerings such as sensors, vibration transmitters, and vibration switches. Faced with the challenge of further growth, a strategic decision was made to develop an offering that would allow the business to enter the systems market.

Universal monitoring module A team of experienced individuals were assembled to build and lead the new Setpoint product line. Within18 months, the Setpoint platform was developed and the first units were shipped. Dozens of innovations were embedded in this new system, including a self-contained “universal” monitoring module (UMM) that could be configured do any required measurements in a single module type – making the addition of new measurements no more difficult than loading a

new app on your smartphone.

In 2011, the Setpoint team added condition monitoring software to its portfolio and entered into a partnership with OSIsoft, - maker of the PI System software. Together, they showed that high-bandwidth, submillisecond vibration waveform data could be streamed directly into a PI database – something that had been routinely dismissed by the vibration industry as “impractical” or even “impossible.”

In less than 12 months, the performance capabilities of the PI System continued along its Moore’s Law trajectory, doubling in speed and making high-speed, online vibration data collection completely practical.

The Setpoint team’s decision to harness the power and installed base of the PI System, rather than developing a standalone condition monitoring infrastructure, has been recognized as insightful and strategic. The PI System is a real time data infrastructure that captures, manages, analyzes, and visualizes, real-time data.

Strategically, the Setpoint team was able to reduce time to market by not re-inventing a real time data infrastructure and simply using the PI System instead. It was also able to tap directly into the huge installed base of PI System users globally, eliminating the need for the customer to invest in a separate condition monitoring software system. This results in significant cost savings by utilizing an already existing software platform in the PI System, instead of making additional investments into IT

and operations infrastructure and maintaining two separate ecosystems.

Growth potential A primary reason behind Setpoint’s strategic partnership with OSIsoft is the elimination of redundant computing, network, and software infrastructure, using the existing PI System to do more for its customers. Another reason is OSIsoft’s ability to envision future market dynamics and Mega Trends that could affect the businesses, economies, and societies of tomorrow. A third reason is that making quick and informed decisions on the condition of an asset requires realtime analysis of large volumes of data, also known as Big Data.

OSIsoft is said to be a leader in Big Data, with the PI System being an integral part of the Big Data ecosystem, converting real-time data into actionable information in critical applications such as oil and gas, power generation, and process industries. Customers use this data as part of their overall plant maintenance and reliability strategies to maximize machinery uptime and productivity.

Performance value The open infrastructure of the PI System enables cross collaboration and knowledge sharing among its partners through a common platform by using a vast amount of historical and real-time data. Capabilities such as expert system anomaly detection, thermodynamic performance monitoring, statistical data mining, reporting tools, Microsoft Office integration, and many others are available through this network of partners

ADVERTORIAL

and their shared use of the PI System as the data infrastructure.

Also, it is more likely that the required application already exists within OSIsoft’s Partner ecosystem.

Setpoint’s smartphone-like approach to hardware and its use of the customer’s existing PI System data infrastructure demonstrates that it is possible to be innovative in this industry by tapping into unmet and unarticulated needs.

The company has recognized the pervasiveness and widespread use of the PI System and offered a solution that replaces a separate condition monitoring silo with the PI System the customer is already using.

In a market characterized by limited technology progress and development, Setpoint’s innovative approach to product development has produced several unique solutions, resolving the most critical challenges of its customers. Users have also responded positively, despite the presence of market incumbents. With its strong overall performance, Setpoint has earned Frost & Sullivan’s 2014 Customer Value Leadership Award.

Each year, Frost & Sullivan presents this award to the company that has demonstrated excellence in implementing strategies that proactively create value for its customers. The primary focus should however be on improving the return on the investment that customers make in its services or products. steve.herbst@prei.co.za

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18.2 Distribute, mix and collect - distribution valve with modular body concept

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odern and compact valve solutions are in demand in plant engineering, for use in a wide range of applications. In addition to demanding requirements in terms of pressure and temperature, modular-style and expandable valve solutions are becoming increasingly popular. Through their adaptability to individual situations, a high level of flexibility can be achieved for a range of different applications with this modular GEMÜ distribution valve.

The GEMÜ 553 series consists of high-quality, stainless steel investment cast bodies that can be very easily connected together in series using a tried-and-tested seal system. In terms of actuator unit, pneumatically operated actuators made of stainless steel or plastic are available from the GEMÜ modular system. These can, depending on requirements, be used in combination with a widely varied range of accessories, such as electrical position indicators, combi switchboxes and/or pilot valves.

Versatile application possibilities Thanks to the diversity of combination options, as well as the technical properties it possesses, the valve can be deployed for a variety of different processes. In this regard, it can be used in applications where an extremely wide variety of different media are distributed, mixed or collected. In particular, the GEMÜ 553 is ideally suitable for the distribution of cooling and lubricating fluids on machine tools.

In the mixing function, media with different properties can be mixed together, such as hot and cold water.

In the collection application, a same medium is guided in the back flow to a common outlet. In the distribution function, a medium is guided to a variety of different consumers.

With the aid of a universal module, it is possible to integrate temperature and pressure measuring directly into the process.

Furthermore, media can be separated along the pipe train. As a result, it is possible to control the flow of two media or types of media (e.g. liquid or gaseous) independently of one another via the same valve configuration.

Thanks to the possibility of locking the individual connections in place in 90° increments, the valve arrangement can be ideally adapted to the most different of process and mounting conditions. Female threads in G1/2 and G3/4 are available for the connections.

The module can be terminated at a desired point through separate connection and blanking flanges. The valve bodies are designed in pressure rating PN 25 and can be quickly and straightforwardly connected together via a threaded connection. When connected, the valve bodies are mutually sealed using O-rings. neels.kloppers@gemue.co.za

Voltage measurements – their importance in motor protection

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nbalanced voltages are unequal voltage values on 3-phase circuits that can exist anywhere in a power distribution system.

Unbalanced voltages can cause serious problems, particularly to motors and other inductive devices. Typically, these voltages may differ by a few volts or more. When voltages differ excessively, problems occur.

For general motor protection, it is always assumed that the system voltage is stable.

This is due to legislations such as NRS 048. This legislation is divided into several parts, mainly guiding the quality of the power supply (QOS), focusing on the voltage parameters, such as magnitude and dip time. However, during fault conditions the system is unstable and

it is essential to know the voltage variation to comprehensively protect the motor. It is generally known that in a fixed power system, there is a 1% increase in current measurement, therefore a 2% increase in voltage.

The sudden fluctuating voltage also contributes to deteriorating winding insulation in a motor, thus reducing the motor life. NewElec has relays such as its NewCode, KE range and others, that measure voltage to ensure comprehensive motor protection. sales@newelec.co.za

IO-Link hub with 16 universal inputs/outputs

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urck’s IO-Link hub brings 16 incoming or outgoing digital signals to the controller via IO-Link. Each port of the TBIL-M1-16DXP can be used as an input or output without any configuration required. This makes the hub particularly suitable for applications which have to link many digital actuators and sensors in a restricted space, such as in pick-to-light systems. The I/O hub can also be used in combination with Turck’s NIC inductive coupler, which can provide contactless data and energy transmission, for the wear-free connection of tool changers to sensors and actuators. The I/O hub even enables the unique identification of the tool without the use of RFID or barcodes. The PNP outputs of the hub are specified up to 0.5 A. The device functions as an IO-Link device (specification v1.1) and can thus be connected to all IO-Link masters. With an extended temperature range from -40 to +70 °C and protection to IP67 it can also be used in outdoor applications. The output function of the hubs can also be deactivated selectively if required. In addition to the new universal hub, Turck also offers I/O hubs with 16 digital inputs and devices with 8 digital outputs. rodneyt@retauto.co.za

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18.2 Flagship control system for Husab

Managing Director Barry Elliott

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ockwell Automation has been selected as the supplier and integrator of the automation control system for Swakop Uranium’s Husab mine near Swakopmund in Namibia. The Rockwell Automation control system will enable control of the complete array of automated leaching plant processes through a 5 500 I/O architecture. The planned 18 month integration phase began in July 2014.

The Rockwell Automation portion of the contract includes the supply and integration of the control and visualisation hardware and software.

Further to this, as part of a five-year frame agreement, Rockwell Automation will supply products for all low voltage variable speed drive, soft starter and intelligent motor protection requirements, and any additional control and visualisation hardware or software requirements.

Guaranteed execution milestones Rockwell Automation was able to guarantee specific timeframes that were in line with strict project delivery requirements. Its solution follows a standardised approach, which enables a high degree of implementation certainty and reliability through strong domain expertise and one of the largest teams of control system engineers in the region.

Rockwell Automation control and visualisation software development will be based on the ISA S88 standard, which allows for enhanced process batching management within the leaching plant.

Complete process solution The Husab Project’s plant areas will be controlled by ControlLogix controllers via a complete Ethernet/IP network layer. Through the Rockwell Automation fully-integrated PlantPAx process automation system, which encompasses the entire control topology from the visualisation layer down to the device layer, the complete set of processes constituting the leaching plant will be controlled.

This includes everything from the conveyor feed into the leaching plant, the crushing of pulverised rock, and the calcining of U3O8 through agitated acid leach.

Having been responsible for other similar control projects, including the automation system controlling the Areva Trekkopje uranium plant, Rockwell Automation has the in-house domain expertise to successfully complete a project of such a nature and magnitude. mjunius@ra.rockwell.com

Index of Advertisers with relevant page numbers Beckhoff Automation OFC, 22, 27 Endress+Hauser 11 Helukabel 5 Honeywell 22, 27 ifm electronic 22, 27, OBC Instrotech 21 Krohne 17

Pepperl+Fuchs IFC Prei Instrumentation 7 RET Automation Controls 22, 27, IBC Sick Automation 9 Temp-Tek 17 Valve & Automation 13 Vega Instruments 15

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Measure, Count, Control and Log Data Now available from RET Automation Controls www.retautomation.com S1

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Tel: +27 (0)11 4532468

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sales@retautomation.com

Call us for the name and number of our distributor in your area.

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