Industry SolutionResygate 1000/3000

Control Systems

Industry Focus

Axiocontrol: New Controller Generation

Machine BuildingIndustry

UPDATE 1 | 15 1

The customer magazine from Phoenix Contact (India) | January–June, 2015

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INCO 2015

Phoenix Contact India organized Sales & Market-ing Meet from 16th-18th July 2015 at the Suryavilas Hotel, Solan in which sales and marketing force from across the country participated.

The event started with the welcome statement by Mr. Dinesh Parwanda, President, Phoenix Contact India. Mr. Rahul Yadav, Vice President, Industrial Components & Electronics division, Mr. Milan Desai, Vice President Control & Industry Solutions division and Mr. S. Palanivelan, Vice President, Device Connectors presented strategy and roadmap for their segments.

This was followed by presentations from different business units. All business units gave briefs about business performance and discussed the upcoming plan and strategies in which other sales team also shared their ideas and feedback of the day to day business. Updates on new products, enhancements to product line, and the future product road-map was also presented and discussed during the conference.

Sales & Marketing Meet - 2015

Phoenix Contact India participated in INCO 2015 which was held in Sri Lanka. The event was organized by The Institution of Incor-porated Engineers, Sri Lanka at BMICH, Sri Lanka from 26th-28th June 2015.

Phoenix Contact India showcased some of its featured products like Wireless range, Safety Relays & Modules, UPS with IQ technology, Quint Oring, Trio, UNO Power Supplies, Cabling solutions, Surge Protection, Terminal Blocks, Tools, Controllers, HMIs, IPCs, Connection Solution, Field Cabling & Solutions for Solar indus-try. Live Demos were also given at the stall.

Phoenix Contact India was selected for the Silver Award of the Stall with the Best Dem-onstration of Products & Services among the stall holders participated at the INCO 2015 Industrial Exhibition & Trade Fair.

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Reader’s Service UPDATEPhoenix Contact (India) Pvt. Ltd. If you need more information regarding any particular product featured in this newsletter, kindly fill this form, scan it and email to us at:response@phoenixcontact.co.in

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02 News

Industry Focus03 Machine Building Industry and Phoenix Contact A strong partner for Machine Building

Housing07 EH…electronics housings for universal use

Field Device Connectors08 PLUSCON data Unique variety for copper and fiber optic cabling

Combicon10 COMBICON Power Innovative connection technology for high-performance electronics

Industrial Field Connectivity11 HEAVYCON Industrial Heavy-duty connectors Power Supplies12 Sensitive Electronics Control…Inferior Power Grid Quality…Increased down- times Uninterruptible Power Supply for DC Systems – Optimizing Plant and System Availability

Interface Components14 CONTACTRON Solid State Contactors – Custom made Hybrid Motor Starters with “n in 1” function Smart Wiring & Clever Switching to switch in a modern way

Industrial Field Connectivity15 COMBI Plug-in Connection Solutions Terminal Block with Plugged Output

Trabtech16 Overload currents securely under control Device Circuit Breakers – Shut-off reliability and system availability, offering a high level of protection, even for longer conductor routes

Marking & Installation18 Topmark Laser Marking solution for complex industrial labeling

IO & Networks19 Axioline Every network, every environment

Industry Solution20 Resygate 1000/3000 Protocol converters for converting serial communication to Ethernet-based communication for the modernization or consolidation of networks.

Control Systems21 Axiocontrol Phoenix Contact’s New Controller Generation: Fast, robust and easy

22 Press Releases

UPDATE 1 | 152 News

Phoenix Contact is closely connected with the machine building industry. Machine building is a global and very dynamic market. Phoenix Contact focuses on the cost effectiveness, quality, flexibility, and performance of ma-chines. Phoenix Contact offers an extensive portfolio of products and services – the decisive contribution to your competitiveness. Phoenix Contact supports its customers – not just before the sale, but also afterwards with extensive after-sales services. Phoenix Contact has a worldwide sales network allows a compe-tent and personal consultation directly on site.

Phoenix Contact focuses on selected trend topics which are very much essential for the Machine Building Industry.• Simply integrate safety technology in your machines.• Avoid expensive downtimes on your machines.• Communicate with your machines through- out the world.• Configure and mark universally using one system.• Reduce your production time with a quick installation.• Reduce your parts variety and lower your warehousing costs. • Assemble machines – modular and flexible.

Simply integrate safety technology in your machines

In machine building, safety technology plays an extremely important role because it prevents harm to the operating personnel and dam-age to the machine. The ISO 13849-1 standard directed at meeting the Machinery Directive results not only in increased requirements for the implementation of safety functions, but also in new opportunities for you as machine builder. With safety components from Phoenix Contact, you are always on the safe side. The devices are particularly easy to handle and al-low you to profit from a quick and economical implementation of safety-related applications. At Phoenix Contact, you will find an extensive safety portfolio for machine building – from conventional safety relays up to network-capa-ble safety solutions. All safety products are easy to install and configure.

Machine Building Industry and Phoenix ContactA strong partner for Machine Building

UPDATE 1 | 15 3Industry Focus

Avoid expensive downtimes on your machines

For you and your customer, nothing is more expensive than a non-operating machine. Standstill times ultimately lead to production downtimes and create very high costs. For this reason, your top priority is machine availabil-ity. To avoid standstill times and production downtimes, reliable components and the high availability of your machine are indispensable. We increase your competitiveness as a machine builder with products that support the avail-ability and, as a result, the productivity of your machine. The devices ensure long operating times and production around the clock. This helps your customer to avoid standstill times and costly production downtimes. We offer you surge protection, device circuit breakers, technologically pioneering power supplies and innovative switching devices.

Communicate with your machines throughout the worldThe global use of machines renders the world-wide communication with machines increas-ingly more important because this allows you to avoid expensive service calls on site. On top of that, state-of-the-art production demands networks that enable the data exchange between all types of processes and machines. Industrial Ethernet is the fast communication standard for an integrated communication between office facilities and production level. Modems and routers connect you to your machines and systems worldwide for efficient remote maintenance, continuous data acquisi-tion and automatic early warning messages. Switches and access points can be used to build powerful Ethernet networks. Security routers and firewalls guarantee data integrity and pro-tect your machine against unauthorized access and manipulations.

UPDATE 1 | 154 Industry Focus

Configure and mark universally using one systemPlanning and configuring control cabinets represents a significant time factor. For this reason, it is an advantage if you can count on professional support. CLIP PROJECT combines the planning software for terminal strip con-figuration with a high-performance marking tool. This allows you direct data exchange with all conventional CAE programs, along with the creation of the complete project documenta-tion. CLIP PROJECT provides the perfect output devices and marking materials for terminal, conductor, device, and system marking. CLIP PROJECT creates an extensive documentation of your projects. It is used for simple imple-mentation at your location as well as the quick order of completely assembled terminal strips and markings manufactured to your specifica-tions. No matter how you decide – CLIP PROJECT will support you.

Reduce your production time with a quick installationAs a machine builder, you are subject to increas-ing competitive pressure. Reduce your costs and assembly times with quick and error-free wiring. Innovative connection technologies and professional tools provide you with significant saving potential in your installation process. Another advantage: Reduced production times also allow you to get the machines to your customers faster. Connection technologies that are quick and easy to operate, such as the push-in connection technology and the SPEEDCON rapid interlock system, reduce the wiring time and minimize the error rate. In addition, use the simple and easy-to-handle tool and expand your advantages even further.

UPDATE 1 | 15 5Industry Focus

Reduce your parts variety and lower your warehousing costs Product solutions that are perfectly matched to each other are a decisive factor for you to keep the manufacturing costs of a machine as low as possible. Our standardized accessories can be used in many product groups. This allows you to reduce your parts variety, lower your warehousing costs and still remain flexible. Standardized products facilitate the commis-sioning and maintenance for your installation and service engineers with uniform design and operating concepts. In the state-of-the-art modular terminal block, relay and automation systems, simply use the standardized acces-sories, no matter whether you want to bridge, mark or test. With CLIPLINE complete, you have a modular terminal block system for all connec-tions. Use the RIFLINE complete relay system to implement all standard relay applications and use the Axioline F I/O system for all common networks.

Assemble machines – modular and flexibleNowadays, one has to guarantee the flexibility of machines because it must be possible to quickly adapt machines to changes of the mar-ket. For this reason, they have to be designed in a modular fashion since modular designed ma-chines guarantee your customers the greatest possible flexibility. To be able to deliver large and large-scale machines to your customers, you also have to design the machines to be modular for transport. For the modular assem-bly of large switching stations and machines, the simple, quick and safe assembly at the target location is particularly important. Plug-in systems in combination with individually con-figurable cable entry systems support you and guarantee the required flexibility.

UPDATE 1 | 156 Industry Focus

Many housing customers demand electron-ics housings that can be used for devices that are available with good aesthetics, innovative features and in the lower pricing range. The EH electronics housings fulfil this requirement.

In addition to the modern design, this housing range excels, thanks to numerous other fea-tures. With 7 overall widths, 2 overall heights, and a range of different cover versions, they are suitable for universal use. Integrated vents ensure good ventilation. The receptacle housing version ensures shock and contamination-proof accommodation of electronic components. A number of PCB guides in the housing provide flexibility for accommodating electronic com-ponents, in both vertical and horizontal mount-ing positions. The device is mounted simply by snapping it onto symmetrical DIN rails accord-ing to EN 60715. Alternatively, wall mounting is also possible. The housings are provided with integrated labeling fields for device marking.

The EH are combined with COMBICON connec-tion technology from the standard range or from the Basicline range. Pluggable as well as fixed connection technology can be used in the widest number of positions and pitches.

Main features and customer benefits• 2 overall heights and 7 overall widths: Enable modular device systems featuring a uniform design.

• 3 cover variants: For application-specific device design.

• Different connection options possible: Provides connection flexibility.

• PCBs can be installed in 3 directions: For a functional device concept.

• Simple PCB shape: Cost-effec- tive PCB production.

• Integrated marking field: For fast device marking.

• DIN rail or wall mounting: Suitable for variety of applications.

• Snap fitting without any tools: Time savings during device assembly.

Target markets• Industrial applications for various devices• Machine building and systems manufacturing• Agricultural machine building• Building management• Infrastructure• General control cabinet manufacturing

Application examples corresponding to the industries mentioned above• Flow meter• Transducers• Angle sensors• Position sensors• Isolators• Interfaces• Frequency controllers• Speed controller• Access control systems• Car park management• Current/voltage controllers and monitoring devices

EH…electronics housings for universal use

UPDATE 1 | 15 7Housing

PLUSCON data is the connector range from Phoenix Contact for safe and reliable data transmission. Benefit from innovative con-nection technologies and an industrial design. The product range includes assembled cables, flush-type connectors, and connectors for field assembly as well as special, tool-free connector systems for copper and fiber optic-based ca-bling. Create consistent solutions for safe data transmission up to 40 Gbps with our range of designs, coding and pin assignments.

Copper-based data ca-bling for networks and fieldbusesComplex automation processes call for high volumes of data at ever increasing transmission

speeds. Benefit now from high-performance connectors and cables for on-site assembly. Whether it’s future-proof high-speed cabling up to 10 Gbps or innovative, efficient hybrid ca-bling we will find the perfect solution for your automation network.

Main features• Up to 10 Gbps• Protection class IP20 to IP69K• 4- and 8-pos. versions• Spring, pierce, and IDC displacement connection• 360° shielding concept• For all common networks and fieldbuses

PLUSCON dataUnique variety for copper and fiber optic cabling

UPDATE 1 | 158 Field Device Connectors

Fiber optic -based data cabling for networks and fieldbusesHigh transmission speed, low attenuation, re-sistance to electromagnetic interference: fiber optic cables are among the modern transmis-sion media for industrial systems and infra-structure applications. Whatever the fiber type or interface – you can choose the right connec-tion technology from our extensive portfolio.

Main features• Up to 40 Gbps• Protection class IP20 to IP65/67• For POF, PCF, and GOF• For all common fiber optic interfaces

Solution for machine buildingPhoenix Contact offers space saving connection solutions for compact machines and systems. Choose your right components and cabling solution for your data transmission system, in RJ 45 M8, M12 or 7/8”, for Ethernet or fieldbuses.Push-pull connectors for assembly are perfect for connecting active components. They can be used in the harsh environments of indoor and outdoor industrial production applications.

Main features• Consistent product range for data transmission up to 10 Gbps.• Connectors that can be assembled without special tools.• Flush-type connectors with litz wire, soldering, and cable connections.• SPEEDCON and push-pull quick-locking technology for easy insertion and removal in the field.

Modular distribution panel for computer centers and con-trol cabinetsPhoenix Contact offers an extensive and forward-looking product range for modern building cabling. Our patch cables and patch fields allow you to install flexible and fail-safe cabling. The modular distribution field with 19” technology can be used individually and in a way that saves space.

Main features• Consistent cabling systems for 19” technology.• Connection solutions for indoor and outdoor applications.• Consistent range of data connectors, right up to active components for building cabling.• GHMT-certified products.

UPDATE 1 | 15 9Field Device Connectors

COMBICON PowerInnovative connection technology for high-performance electronics

Phoenix Contact introduces a vast product range for you power electronics based on innovative connection technologies which are much faster, simple and easier to use and thus increase the ef-ficiency and productivity of the whole system by saving valuable time, cost and space.

COMBICON power product range offers plug-in connectors, PCB terminal blocks, and feed-through terminal blocks enable users to choose from 16 A to 309 A. The existing COMBICON power product range has been enhanced with new and highly featured products mentioned below:

TW 95 high-current panel feed-through terminal blocksThe new high-current panel feed-through termi-nal blocks from the TW series can accommodate conductors up to 95 mm² , thanks to its innovative TLOX connection technology (toggle lever prin-ciple) which is implemented outside the device.

DIN rail bracket for IPC 16 and IPC 35 Power connectorsThe high power connectors IPC 16 and IPC 35 can also be mounted onto DIN rail with the help of new DR 16 & DR 35 series DIN rail brackets inside the control cabinet applica-tions. Customers are allowed to establish a convenient, plug-in wire-to-wire connec-tion on the DIN rail with the help of counterpart PC 16 and PC 35 compatible with IPC 16 and IPC 35 series power connectors.

Target markets• Infrastructure• Industry• Machine Building

Application areas• Solar Invertor• Smart Meter• Invertor for wind turbines• Frequency convertor• Servo controller• Filter• Control Cabinet

MKDSP 95 PCB terminal block COMBICON power product spectrum introduces the world’s highest-performance PCB terminal block: the “MKDSP 95” which facilitates conduc-tor cross section of up to 95 mm² connected reliably and conveniently. The PCB terminal block is wave soldrable and offers ratings up to 232 A, 1000 V in accordance with IEC 60947-7-1; unlimited 600 V UL approval in Use Group C is achieved in accordance with UL 1059. The prod-uct replaces the typical costly copper rail mount-ing used in high-current applications.

UPDATE 1 | 1510 Combicon

HEAVYCONIndustrial Heavy-duty connectors

HEAVYCON connectors can be used in the most ex-treme conditions, including being subjected to dirt, water, vibrations and high mechanical strain. They remain sealed up to IP69K degree of protection. The robust plastic and metal housings are available with a single or double locking latch or with screw lock-ing. In addition to terminal adapters, contact inserts with different connection methods are available in versions with a fixed number of positions and in modular form for side-by-side mounting.

High degree of protection, quick and easy assembly, and a particularly robust design –these are the key features of heavy-duty connectors from Phoenix Contact. The entire HEAVYCON product range con-sists of housings, contact inserts, cable glands, and accessories. Depending on the application you can select a STANDARD, EVO, or ADVANCE housing.

The STANDARD housing requires a panel mount-ing base for the panel feedthrough and features a convenient locking latch for frequent insertion/withdrawal cycles.

We also offer the HEAVYCON ADVANCE series. Here, for the panel feed-through, the traditional panel mounting base is replaced by two simple panel mounting flanges, and the locking latch is replaced by two robust M6 locking screws. The direct mount-ing of the housing onto the mounting wall using only one conductive seal also offers EMC related advantages.

Both housing series fit on the same panel cutouts. The contact inserts (fixed inserts,combination inserts, and modular contact inserts) can be used in both housing systems equally. If you are fre-quently plugging/unplugging connectors, we recommend the HEAVYCON STANDARD. If you are rarely plugging/unplugging, only plugging/unplugging for startup, if the housing has to be extremely

robust, or if it needs to be possible to walk on the housing, we recommend HEAVYCON ADVANCE.

HEAVYCON ADVANCE heavy-duty connectors with screw locking are especially well suited for demand-ing requirements in aggressive environments. The panel mount-ing base typically used has been replaced by a panel mounting flange, thereby reducing assembly and material costs. The ADVANCE plastic housing withmolded cable glands offers additional potential savings. The ADVANCE range is rounded off with the AL sup-porting base elements for universal use.

Switch to HEAVYCON EVO now and save on storage costs. You can use the diagonal EVO cable input to save up to 70% of vari-ants. The use of high-quality ma-terials and full compatibility with the industry standard enable failsafe use in a wide range of applications. Depending on the application, select a cost effective plastic housing or a robust metal housing. The new metal series of the EVO connector has all the advantages of the EVO plastic housing. The housing surfaces and seals are also electrically conductive and, therefore, also EMC-protected. The metal cable glands provide increased con-ductor pull-out forces.

The new HPR series of heavy-duty connectors consists of aluminum housings with screw lock-ing. The series B hous-ing features a high degree of vibration resistance and IP69K protec-tion. This makes it especially well suited for special fields of application such as railway technology.

HEAVYCON STANDARD

HEAVYCON ADVANCE

HEAVYCON EVO

HEAVYCON HPR SERIES

UPDATE 1 | 15 11Industrial Field Connectivity

Uninterruptible Power Supply for DC Systems – Optimizing Plant and System Availability

Sensitive Electronics Control…Inferior Power Grid Quality…Increased downtimes

An inferior power grid quality along with the growing use of sensitive electronics has led to increased downtimes. There is a competitive advantage to be had where the production pro-cess runs smoothly even when the grid quality is deficient. Special attention should therefore be paid to the power supply, which is the core of any installation. In this way, unexpected costs due to voltage drops can be avoided in advance.

Voltage interruptions affect the production process: they lead to loss of data as well as a breakdown of the control system, resulting

in expensive damage to equipment and the product when a machine restarts automatically. Even short downtimes can lead to high costs. In such cases, investment in uninterruptible power supplies (UPS) pays off in a very short time.

Scenario of power supplyPlant operators all over the world are faced with unstable grids that necessitate the use of power supplies with a high failure bridging time, buffer modules or uninterruptible power supplies. According to breakdown statistics,

UPDATE 1 | 1512 Power Supplies

breakdowns in the medium voltage grids are due to the following reasons: weather condi-tions, short circuits, line interruptions or techni-cal failures. Almost half of these breakdowns lead to interruptions in power supply.

UPS FOR DC SYSTEM Sensitive Electronic controls...Inferior power GridPhoenix Contact offers a complete product con-cept for a more reliable power supply: all power supplies of its Step, Mini and Quint models offer a power failure bridging time of more than 20 ms under full load.

The Quint DC-UPS provides long buffer times along with VRLA, LI-ION and CAP Power storage batteries. They are especially suitable for an uninterrupted supply to control units, machines and systems with high downtime costs or those where the downtime could damage expensive products and equipment.

The new generation device from Phoenix Con-tact is now equipped with the IQ technology. It provides the necessary information to ensure the stability of the supply at any time with optimum utilization of the battery. In all cur-rently available solutions in the market, there is always one point unknown: sufficient informa-tion of the energy storage.

IQ Technology provides informa-tion on charge status and life expectancyThe intelligent Quint UPS-IQ determines all relevant states of the battery. It offers the indis-pensable transparency to guarantee the stabil-ity of the supply at any time and with optimum utilization of the battery. You can easily set the parameters thru UPS CONF Software in your PC. The intelligent battery management knows the current state of charge of the battery connected

and calculates the available remaining time. Accordingly, supply sufficient power to other connected equipment and Industrial PC. The time required for shutdown of the PC is set thru software and an early shutdown of industrial PCs can be avoided.

The remaining life expectancy of the battery is known. This allows servicing to be planned. If the battery is replaced at the ideal time, costs are also avoided that would occur by replacing the battery too early or after failure.

Minimum downtimes offer a definite competi-tive advantage. Phoenix Contact offers a com-prehensive product range for a reliable power supply that enables individual solutions for a smooth production process.

UPDATE 1 | 15 13Power Supplies

CONTACTRON Solid State Contactors – Custom made Hybrid Motor Starters with “n in 1” functionSmart Wiring & Clever Switching to switch in a modern way

Electric motors are used in a variety of

industrial applications for controlling movements.

The motors are often started using mechanical contactor circuits. Besides

the advantage of the low price, the conventional contactor

technology also has major disadvantages such as high space requirements, limited service life and the need for considerable wiring. The new, innovative CONTACTRON hybrid technology offers a cost effective and technically superior alternative to the conventional contactor tech-nology. It provides space saving, considerably less wiring,ten times longer service life and various selectable functions.

The CONTACTRON range offers electronic solutions for switching, reversing, contacting and monitoring of motors. It includes Solid-state contactors (3 Max. 37Amp & 1 Max. 50 Amp), Solid-state reversing contactors (3 Max. 37Amp), Hybrid solid-state contactors e.g. “4 in 1” hybrid motor starter (3 Max. 9Amp), Hybrid Motor Starter with fuse protection, Motor man-agers, Profibus couplers and DT Smart Wiring.

CONTACTRON with new options for fieldbus integration

Integration into fieldbus systems is handled using an IFS system con-

nection or using the Smart Wire DT wiring System. Corresponding

gateways are available for all common fieldbus systems. It provides:• Simplified control wiring via

DIN rail connector.• Easy integration of your motor

control application into conventional bus systems using IFS gateways.• High system availability by optimizing service intervals based on process data.

ApplicationsMachine and system engineering 3-phase AC electric motors for driving con-veyor belts, freight elevators, tool processing machines, pumps, etc., all play an important role in mechanical engineering. The Hybrid Motor Starters have 10 times better service life than mechanical contactors, save a great deal of space and quick wiring.

Conveyors, freight elevators and high-rack warehousesIn modern conveyor systems the failure of individual drives may lead to downtime of the entire system. However, the short circuit-proof Hybrid Motor Starters ensure a high level of system availability Hence, the customer benefits from a fast restart of the machine or system.

Pumps in the water/waste water industry, food and chemical industriesElectronic devices located in environments with liquids/fluid media are at the greatest risk of short circuiting. The systems may be flooded more frequently which can trigger short cir-cuits. In these applications, short circuit proof motor start devices are suggested because the device is usable again.

The CONTACTRON solid-state reversing contac-tor “n in 1” works with the hybrid technology and offers motor protection and a safety function besides a complete reversing contac-tor circuit for a motor – all this integrated in a single device no wider than your thumb.

UPDATE 1 | 1514 Interface Components

COMBI Plug-in Connection SolutionsTerminal Block with Plugged Output

From the control cabinet to a complete system- it is impossible to imagine today’s applica-tions without plug-in solutions. It is here that the COMBI plug-in solutions. From supplying the control cabinet and the power & control components, right up to the quick installation of distributed system parts, the COMBI Plug-in system always delivers the perfect solution.

The COMBI pluggable terminal block is a modular DIN rail mounted terminal block which provides for a standard terminal block connec-tion on one side and a plug connection on the opposite. This is an especially popular terminal block for those applications requiring multiple wires to be connected and disconnected at the same time, such as when connecting to a con-trol device. It can also be used in those applica-tions where you would like to have complete modularity in the system, not only with the ter-minal blocks but also with the wiring, to insure ease of installation, maintenance and testing. Its distinguishing feature is its standardized plug-in zone. This makes it possible to combine basic terminal blocks, which are available with screw, push-in, spring-cage & fast connection technologies in any way.

The Plug-in ring feeders guarantee the safe supply of power between the control cabinets. Free-hanging couplings are not only suitable for wiring in the smallest of spaces; they can also be used to lengthen pre-assembled cables without any problems. The COMBI base strips enable the plug-in wiring of electronic devices or components.

FeaturesFlexible & plug-in capable The COMBI family offers a free choice of connection methods. The standardized COMBI plug-in zone allows terminal blocks & connectors to be connected to suit the application regardless of connection method.

Powerful contactThe COMBI family con-nector system enables a plug-in wiring solution up to a nominal current of 32 A & a nominal voltage of 800V. The contact system features an integrated overspring to enable it to withstand extreme vibration levels.

Touch proofThe COMBI system offers outstanding user protection since both the basic terminal blocks & the connectors are touch proof. Along-side the safety aspect, this offers great flexibility for configuration work: the supply may be routed via the terminal blocks or connectors.

Applications• Connection of sub-assemblies.• Cabinets made of multiple separate modules.

UPDATE 1 | 15 15Industry Cabinet Connectivity

Overload currents securely under controlDevice Circuit Breakers – Shut-off reliability and system availability, offering a high level of protection, even for longer conductor routes

In the machine building industry, machine safety must fulfill high demands. Reliability and availability play an important role in continu-ous production processes. In order to ensure safety of personnel and to protect the equip-ment and plant/systems, an over-voltage and short-circuit protection concept complying with current standards is required. This is now became essential for plant with or without the danger of explosion.

Energy efficiency is an increasingly important goal in the planning and operation of systems. Intelligent control concepts and high availabil-ity of electrical systems are also becoming more and more important. To combine availability and efficiency, the right power distribution solution must be chosen early on during the planning stage.

Generally AC circuit breakers are used unmind-fully even in DC circuits without analyzing the fact that it could lead to unwanted breakdown. This breakdown can be prevented by using specific DC circuit breakers or switches.

Device protection products must meet two ba-sic requirements: Easy installation and reliable, selective shut-off of individual load circuits in the event of a fault. These core prerequisites dictate how the device protection switches are designed and electrically engineered. Phoenix Contact DEVICE CIRCUIT BREAKER meets such features and have many more essential and diagnostic features.

Device protection switches or cir-cuit breakersDevice protection switches and circuit breakers are often considered the same, but their func-tions are very different. According to standard DIN EN 60898-1, circuit breakers are intended for “household installations and similar appli-cations.” They are primarily used for protecting cables. Device protection switches are mainly for protecting against short circuits and over-loads, while also offering cable protection, as described in standard DIN EN 60934.

Device Circuit Breaker

UPDATE 1 | 1516 Trabtech

Phoenix Contact have three vari-ants to offer to the industry for short circuit protection for the control circuits1. Thermal Circuit breaker (TCP): Protection against overload2. Thermo magnetic Circuit breaker (TMC): Protection against overload & short-circuit.3. Electronic Circuit breaker: Protection against overload , short-circuit & attenuation

Features• Cable and device protection• Pluggable • modular extension• individual adaptation• Resistant against high inrush currents• Protection of wires and devices In accordance with DIN EN 60934 In accordance with UL 1077, 2367• Status Indication• Remote settable

Reliable selective shut-offThe most important characteristic during use in an application is shut-off capacity. The primary task of a device protection switch is to selec-tively shut off a circuit containing a defective device. Selective shut-off means that the defec-tive load is shut off without impairing the other end devices connected to the power supply. The load can only be shut off if the shut-off condi-tions have been met.

ConclusionDevice protection switches must meet two basic requirements. First, they must be modular in design and easy to install. This minimizes installation time and increases flexibility of application. At the same time, switches must be

available in electronic as well as thermomagnetic versions with different tripping characteristics to ensure the best value for money in any application. The goal is always reliable shut-off in the event of a fault, leading to increased system availability.

Electronic multichannel circuit breakers

Active current limiting protects against overloads and short circuits

Device Circuit Breaker Board

UPDATE 1 | 15 17Trabtech

The powerful ytterbium fiber laser, labels the marking material (stainless steel V4A), alumi-num, and plastic) directly. As the markings is done directly on the material there is no toner or ink ribbon required. The labels are extremely durable even in extreme conditions and envi-ronmental influences. The machine marked and cut polyacrylate material in one easy operation according to individual specification.

The machine automatically detects the material in use, increasing both the speed and efficiency of your operation. Not only that, the Topmark laser works with the Clip Project planning and labeling software, making it the fastest desktop laser machine in its class. It’s simple to use, with none of the special laser knowledge or time-consuming parameter, adjustment as required by other lasers.

Major benefitsResistance Perfect marking due to pulsed fiber lasers. Max-imum wipe and scratch resistance, resistance to oils, chemicals, and solvents as well as UV light.

Simplicity All marking materials such as plastic, metal, and polyacrylate can be marked without presets. Also large selection of UCT (PC)and metal (AL and V4A), for use in almost all industrial ap-plications.

Efficiency 7140 labels can be created without an operator in just 28 minutes.

DurabilityTopmark Laser is highly durable and resistant to wiping. And since the marking is applied to the material itself, it can only be removed by destroying the material. Laser marking provides especially high durability as, in contrast to other printing technologies, no marking medium is applied to the target material; instead, the laser beam alters the material itself.

Topmark LaserMarking solution for complex industrial labeling

The new TOPMARK laser machine from Phoenix Contact offer the perfect terminal, conductor, cable, device, and system label for every application.

UPDATE 1 | 1518 Marking & Installation

Phoenix Contact offers a wide range of I/O system for different field buses. Whether in the control cabinet or in the field, whichever network you use – with our Axioline I/O system you get the right I/Os.

Axioline F is the I/O system for the control cabi-net and Axioline E is the new I/O product range for field installation. Regardless of the design, Axioline operates all leading networks: PROFI-NET, EtherNet/IP™, EtherCAT, sercos, Modbus TCP, and PROFIBUS. All I/Os are quick as regards response time, robust in terms of their design, and very easy to operate. This supports a wide range of applications and greater flexibility.

Advantages• Increased machine output, thanks to fast and synchronous signal acquisition• Extremely robust – thanks to the excellent EMC design and sturdy mechanical construction• Quick and easy installation, thanks to push-in connection technology, SPEEDCON rapid interlock system, and M12 power• Maximum flexibility, thanks to network openness and the wide range of functions for control cabinet and field installation

There is a growing trend in modern automation technology toward Ethernet-based communica-tion protocols. They are ideal for applications in which response time and synchronism are particularly important. The focus is increasingly on deciding factors such as speed and robust-ness, as well as easy handling. Based on these requirements, the Axioline I/O system offers components for all common Ethernet systems. In addition, the Axioline I/O system compo-nents support PROFIBUS DP.

You can now also implement safety applica-tions with Axioline F. Based on PROFINET and PROFIBUS, these new PROFIsafe modules can be used to acquire and output safety-related signals.

Full integration into the controller manufactur-er’s engineering tool and the easy, channel-spe-cific parameterization shorten your engineering process, and save time during startup. The channel-specific diagnostic message and easy acknowledgement process also increase system availability.

AxiolineEvery network, every environment

UPDATE 1 | 15 19IO & Networks

Resygate 1000/3000Protocol converters for converting serial communication to Ethernet-based communication for the modernization or consolidation of networks

The administrative amalgamation of water, electricity by municipal works and network operators makes it necessary to consolidate the heterogeneous processes in a new control sys-tem. The modernization of the existing process technology in the stations on site can often only be achieved step by step, as the various plants use different protocols and have to be adapted for connection to the control system. Within the scope of this type of modernization, the Resygate protocol converter can be used to reorganize existing remote control structures by means of subnetworks and new IP address areas.

Resygate converts serial and/or TCP-based remote control protocols into the standardized IEC 60870-5-104 and IEC 60870-5-101 Balanced protocols. Resygate acts as protocol converter for universal use and as a data supplier with a network-capable process connection. In addi-tion, it can be used as a protocol converter or substation for network-isolated connections between control systems.

The Resygate series includes two device classes which differ with regard to their interfaces and process variables/data points. Both devices support the following protocols as standard: IEC 60870-5-104, IEC 60870-5-101, Modbus/RTU and Modbus/TCP, also possible on request is IEC 60870-5-103, SINAUT

Modernization of the remote con-trol infrastructureThe modernization of the control system and conversion to Ethernet is usually implemented step by step. This often means that existing remote control lines must initially remain in-tact and they are then successively modernized afterwards. The challenge here is that existing protocols still need to be supported. Also, most part control systems only support one protocol.The solution comes in the form of converting different remote control protocols to the pre-ferred target protocol for the control room.

Consolidation of supply networksWhile required to replan the network, the costs associated are high and the resources avail-able are limited. The challenge is to expand the network in the most inexpensive way while conserving resources (limited IP address area). Resygate converters can be used for extending the IP address area by creating subnetworks.Whether a new installation or modernization: with Resygate and an industry-specific product portfolio from Phoenix Contact, comprehensive solution concepts can be imple-mented.

IEC 60870-5-101 bal

IEC 60870-5-104

IEC 60870-5-101 bal

IEC 60870-5-101 unbal

IEC 60870-5-104

Modbus/RTU

Modbus/TCP

Resygate

UPDATE 1 | 1520 Industry Solution

Easy start-up, instant and continuous provision of process data, and a long, reliable service life are key factors in the quality of automation components. This is directly reflected by the availability of the machines and plants that these components are installed in. That is why, when designing its new generation of Axio-control controllers, Phoenix Contact focused on easy handling, rugged design, and fast data processing and transmission.

Phoenix Contact offers these controllers as compact controller (AXC 1050) and high-per-formance controller (AXC 3050). In combina-tion with the Axioline I/O system they form a complete automation system for implementing easy or highly complex automation tasks. The AXC 1050/XC compact controller can be used in especially demanding environments with an extended temperature range of -40° to +60°C.

Fast Response TimeWith a processing speed of 90 microseconds per 1000 instructions (data type: bits), the AXC 1050 is particularly suitable for small and medium-scale control applications. The AXC 3050 controller offers extremely fast count-ing processes and event processing: separate processing relieves the CPU and counters and events can be processed with maximum speed.

Fast AccessWith integrated USB interface, the Controllers can be parameterized / programmed without knowing the IP address. Wiring of the Axiocon-

trol controller is easy, too: the push-in technology enables easy wiring without requiring tools. Us-ing the simple start-up software tool - Startup+, wiring can be checked and prevent the erroneous wiring. This simplifies installation, saves time and cuts cost.

High Level of RobustnessThe Axiocontrol series controllers feature particu-larly robust housing and electronics. The excel-lent EMC design ensures safety in harsh ambient environments. Even with extreme vibrations, signal lines connected to the I/O module of the controller do not loosen accidentally. The system is continuous shock- resistant up to 10 g.

The Axiocontrol PLC and the Axi-oline I/O system not only make the machine or system faster, they also make it more rug-ged and easier to use. Special electromagnetic proper-ties (Class B interference emission), the mechanical design, the technologies used, as well as systemic functions such as the built-in UPS and the extended temper-ature range all help to increase the overall reliability of the application. In this context, the AXC Controllers can significantly increase the machine or system’s avail-ability as well as its service life - without requiring significantly higher investment costs.

AxiocontrolPhoenix Contact’s New Controller Generation:Fast, robust and easy

UPDATE 1 | 15 21Control System

Safe data transmission in the field

Identification of power plants

Powerful 19-inch industrial PCs for data centersPhoenix Contact’s new industrial PCs

housed in standard 19-inch racks are an ideal solu-tion for reliably captur-ing, measuring, visualiz-ing, and processing large

volumes of data. Thanks to their standardized format

they can be installed in any 19-inch rack switching cabinet, where they can be used to handle a wide range of complicated tasks.

To suit differing requirements and size limita-tions, the industrial PCs are available in heights

of two- or four-rack units. The new 4th genera-tion Intel processors provide all the necessary computing power, which is matched by RAM capacities of up to 16 GB and data storage of up to 4 TB.

Furthermore the rack PCs feature PCI/PCIe slots for expansion. RAID support (0/1/5/10) ensures excellent system availability and data security. Thanks to the built-in hot-swap drives (two or three drives), maintenance is very easy, and the lockable front cover prevents unauthorized access.

The new push-pull Advance data connectors from Phoenix Contact bring future-proof high-speed cabling directly to the field.

Designed for data rates of up to ten Gbps, the connectors are protected against dirt, dust or humidity by means of IP65/IP67 protection. Due to their 360° shielding, they are also immune to electromagnetic interference.

The push-pull technology means that users can insert and remove the connectors easily. Nevertheless, a mechanical locking mechanism reliably prevents unintentional release of the connection.

The series includes versions for Profinet and Ethernet as well as fiber optic versions for POF, GOF, and PCF fibers. All connectors are designed for conductor cross sections from 26 to 22 AWG. Both the straight and 45° angled versions are suitable for cable diameters up to 9.5 mm.

Phoenix Contact’s multichannel electronic CBM circuit breakers protect electrical systems against overloads and short circuit currents – at a very compact component width of just 41 mm. The device’s built-in rated current assistant makes it significantly easier to configure the rated currents for the connected loads.

In addition, the two new circuit breakers – with four and eight channels, respec-tively – provide electronic locking of the

settings entered for the rated currents. This pre-vents accidental changes of the device settings. The rated current can be set stepwise from 0.5 A right up to 10 A for each channel, which makes it much easier to select suitable protection

devices. A set of LED signals continuously indi-cates the statuses of the connected devices as well as the power supply to the circuit breaker itself. The circuit breaker is able to detect and signal underloads and overloads, and it can switch off the connected loads according to a predefined procedure. The signaling concept greatly simplifies the troubleshooting of down-stream system components.

The current of each channel is actively limited to ensure the best possible load distribution, which makes it possible to use smaller power supplies. These electronic circuit breakers are particularly suitable for machine, control, and plant systems, thanks to their wide tempera-ture range, the use of push-in connections, and excellent shock and vibration resilience.

UPDATE 1 | 1522 Press Releases

Identification of power plantsPhoenix Contact has extended its system mark-ing range with a coordinated system of marking labels, colored media marking labels according to DIN 2403, label holders, and corresponding fixing material. The power plant identification system (KKS) is an identification system for the uniform and systematic identification of power plants.

The marking labels are available as a basic ver-sion and as an intelligent version with inte-grated RFID HF or UHF transponder and offer numerous advantages. This technology makes maintenance and identification work more efficient and user-friendly, with even more

New relay modules for environments with explosive atmospheresThe 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 approv-als 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 connec-tions, 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 addi-tion, wiring of the components can be further simplified through the use of adapters when connecting to the system cabling.

GL approval for the QPD installation system(07/14) The QPD installation system with Quickon IDC fast connection technology from Phoenix Contact now has GL approval for the complete QPD product portfolio. Use in very harsh and aggressive environments, such as on ships or in offshore wind power plants, is therefore possible.

The fast connection technology of the installa-tion system, with up to 80% time savings dur-ing installation when connected in the field, is of particular advantage in this field of applica-tion. For installation, the cable sheath is simply removed and the litz wires are arranged in the

splice body, cut flush, and screwed. No special tools are required.

Another advantage is the robust design and therefore the flexible use of the product. They satisfy the requirements of protection classes IP68/IP69k and IK07 impact strength. The approved product portfolio includes panel feed-throughs, cable connectors, connectors, and H and T-distribu-tors and is suitable for all cross sections from 1.0 - 6.0 mm².

options for servicing and maintenance.

Thanks to the Bluemark CLED marking system, the new system labels from Phoenix Contact can now be printed with or without RFID transponder, in addition to the existing product range. The system satisfies the requirements of power plant environments, which means that it can withstand high thermal, chemical, and mechanical loads.

UPDATE 1 | 15 23Press Releases

UPDATE 1 | 1524

Phoenix Contact (India) Pvt. Ltd. F-26/2, Okhla Industrial Area Phase-II, New Delhi 110020 INDIATel: +91-11-30262700 / 800 | E-mail: newsletter@phoenixcontact.co.in | Website: www.phoenixcontact.co.in

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