what’s new in process technology apr 2012

http://www.weidmuller.com.au

http://www.kaeser.com.au

ON THE COVER 0412CONTENTS

WHAT'S NEW IN PROCESS TECHNOLOGYAPRIL 2012

Weidmüller has released its new IES series

of Industrial Ethernet switches to supersede

its existing range. Reliable, sophisticated

and functional, the new series has been

designed to meet the increasingly complex

and demanding tasks of monitoring and

controlling operational data.

With three ranges to choose from, the series

offers a broad choice of Fast Ethernet or

Gigabit Ethernet managed switches with

various port combinations. Users can select

from the entry level IES21 Fast Ethernet or

the IES31 Fast Ethernet with Gigabit Uplink,

up to the IES41 full Gigabit Ethernet switches.

Offerring a broad range of functionality, the

switches feature ring redundancy with floating

master, the latest security features, IGMP

snooping and a built-in virtual cable tester.

Suitable for use in the factory, automotive

process and oil, gas and renewable en-

ergy industries, the family meets all current

Australian standards. It delivers exceptional

performance and reliability, thanks to a range

of advanced features.

Equipped with the all-new W-Ring technology,

the IES family delivers far more redundancy

and greater reliability than previously. W-Ring

simplifies network requirements by eliminat-

ing master/slave settings in a redundant ring,

while providing a network reinstatement time

of less than 20 ms.

The switches can be operated in harsh and

demanding environments and have been

created to withstand operating temperatures

up to 85ºC as well as excessive vibration.

Housed in robust metal casings with no need

for fans or case venting, the family is IP40

protected. Highly compact, the switches can

be DIN rail- or wall-mounted.

Weidmuller Pty Ltdwww.weidmuller.com.au

4 TheDNP3protocol Advantagesforwaterandwastewater

telemetrysystems

8 Newproducts

14 Hotproductsonline

18 Cleverpumping Drivemodulesspeciallydesignedfor

pumpingapplications.

34 Redundancyinindustrialnetworks

Part2

42 AsIseeitNationalOHSharmonisation:Willitarrive?

Your copy of What's New in Process Technology is now available as an online eMag.

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THEDNP3PROTOCOL

ADVANTAGESFORWATERANDWASTEWATERTELEMETRYSYSTEMS

DNP3, or Distributed Network Protocol, has beenaround for close to two decades now. It wasdeveloped by Westronic in 1993, primarily for thepower industry.

4WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au

Vishal Prakash

different groups called ‘class’. The protocol currently supports four classes of data - 0, 1, 2 and 3. Class 0 data is real-time data. Classes 1, 2 and are reserved for objects that require timestamp information (event data). Each class of data is independent from the other. A class of data also has variation parameters which allow the user to select the type of value, time and diagnostic information to be recorded.

This DNP3 protocol feature is extremely useful, especially in multilayered systems as it allows the user to categorise field data. For example, normal conditions at a pump station site, like pumps starting and stopping, may be configured as Class 2 type events. Thus, when the pump changes state, an event will be created as a Class 2 type event and stored in memory. Since this is normal operation, an unsolicited report (or Report by exception) need not be initiated to a DNP3 master device. When the master device performs a routine background poll, it can recover all Class 2 events.

But assume at the same pump station site there is a pump fault indication. This is, in most cases, a critical alarm of which the DNP3 master needs to be aware, so that appropriate action can be taken. Thus, the pump fault status indication can be configured as a Class 1 event, thereby triggering an unsolicited report to the DNP3 master device.

DNP3 protocol’s fundamental support for data classification allows the end user to design and operate an efficient telemetry system irrespective of the type of communications media being used.

Report by exception (unsolicited reporting)Report by exception refers to a remote device’s ability to initiate communications to a top-end master. Traditional telemetry systems are typically poll-only systems. In medium-to-large systems, a polling proto-col can lead to loss of data. To prevent the loss of data, communications bandwidth would have to be increased constantly.

Taking the example described above, with DNP3 protocol’s inherent support for

From its inception, DNP3 has been an open protocol, allowing end users to use a common protocol across many hardware platforms.

It has a number of features and advan-tages, however, the features described below are particularly useful for water and wastewater applications.

Open protocolThe guardian of the DNP3 protocol is the DNP3 Users Group Technical Committee, which was formed in 1995 and is vendor independent. The committee’s charter not only includes specifying protocol enhance-ments and new functionality called 'DNP Subset Definitions,' but ensures there is backward compatibility and absolutely makes sure there are no vendor specific variants of the protocol. The firm compli-ance requirement ensures that hardware and software manufacturers who do support DNP3 do so within very well defined parameters. It should be noted that a vendor need not support all DNP3 protocol functionality. The compliance to DNP3 can be via three different levels - 1, 2 and 3. All vendors who support DNP3 must make available a device profile docu-ment that clearly lists the DNP3 features supported by the product and thus the compliance level.

Classification of field dataIn a water or wastewater system there are various assets that require monitoring and control. These include treatment plants, pump stations, valve sites, canals, weirs, tanks, ponds, dams, reservoirs, pipelines and much more. At these locations, a great deal of normal day-to-day activity exists. For example, at a pump station, it is very normal for the pump to go ON or OFF when the configured conditions are true or false.

The question is - do you want every event reported to the top end? The answer is no, because this will take up bandwidth and, possibly, prevent information on critical events from getting through to the DNP3 master device.

To prevent this scenario, DNP3 protocol allows users to classify their data into

APRIL 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5www.ProcessOnline.com.au


PSTNCloud

Ethernet

DNP3 Master

Radio

DNP3 Outstation Devices

Fiber Optic Ring

PSTN (Modem)

Telemetry

unsolicitedreporting,thepumpfaultalarmcanbesenttotheDNP3masterimmediatelyupon occurrence. If the telemetry systemwere a poll-only system using a differentcommunications protocol, the alarm infor-mation would only be seen at the top-endaftertheoutstationhasbeenpolledbythemaster.Andevenwhenthemasterseesthepumpfaultstatusindication,itwillnothavethe event timestamp information.

Timestamped dataTimestampeddataisalsoknownasevent-loggedorevent-baseddata. It is,basically,where an event such as a pump changingits status from ON to OFF, or a change inthetanklevelbyacertainpercentagewithina specified time period, will be recordedin the device with a time and date stamp.Soundssimple…well,itissimple,becausetheDNP3protocolspecificationdictateshowthe timestamping is to be done andwhichparametersaretoberecorded.Thisstandardhas to be maintained by all vendors thatclaim to support DNP3 protocol.

Havingaccesstotime-stampeddataforan end user is hugely valuable:

•Many telemetry systems are poll-onlysystems for a number of reasons -geographical, or by virtue of design,whichmeansthatwithouttimestamping,if an event occurs and the device isnot polled at that instant in time, theevent will be lost. Now, an event likeachangeofpumpstatuscanbestoredas thenumberof times thepumphascomeONandthenumberoftimesthe

pumphasgone to theOFFstate.Thisis useful information, but it does notprovide the time the pumps went ONandOFF.Thetimeinformationisusefulfor analysis such as the times duringthe day the pumps start.

•In theeventofacommunications fail-ure, a device can continue to recordtheeventsandstorethem inmemory.Once the communication system hasrecovered,atop-endmasterwillbeabletoretrievetheseeventsandgraphicallydisplay, accurately, the events thatoccurred during the communicationsfailure.

Time synchronisationTheDNP3protocolsupportstimesynchro-nisation. A DNP3 outstation device can beconfigured to send a time sync request tothemasteroraDNP3mastercanperiodi-cally send a time sync command to DNP3outstationdevices.TimesyncispartoftheDNP3protocolspecification.Keyadvantagesof the time sync function include:

•Accurateandreliabletime-basedalarminformation from a remote device.

•Scheduling accuracy - for example,when to switch over from duty tostandbypump;generatetestunsolicitedmessages at a particular time.

Secure authenticationAscriticalinfrastructure,waterandwaste-water systems must be secured. Therehave also been a few well publicised anddocumented instances of SCADA security

breachesthathaveaffectedtheperformanceof the systems.

The DNP3 protocol includes IEC62351version2authentication.DNP3secureau-thenticationallowsaDNP3slaveormasterdevice to unambiguously determine if itis communicating with the correct DNP3master or slave.

In water and wastewater systems it iscommon to issue pump/valve (or similar)operatecommandsfromthetop-endmaster.Withoutauthentication,itiscompletelypos-sible for someone to intercept a messageand relay with modified settings. DNP3Secure Authentication overcomes this is-sue, as the DNP3 outstation challengesthe DNP3 master to see if the commandtooperatecomesfromalegitimatesource.TheauthenticationkeyisupdatedregularlybetweenaDNP3masterandoutstation.ThiscommunicationisseparateandnotpartofstandardDNP3datatransfermessages.Ifanoutstationdoesnotreceiveanupdatedkeywithina specifiedperiodof time, or if thekey is invalid, then the control commandsfrom the DNP3 Master, even if valid, willnot be executed by the outstation device.

The DNP3 protocol also uses a morebasicformtoensurecontrolcommandsareexecuted correctly. This is called 'select-before-operate.'Inthiscase,aDNP3Masterwillfirstsenda'select'command,towhichtheoutstationdevicewillrespond,andthen,if the outstation device does not receivethe 'operate' command within a specifiedamount of time, it will not execute thecontrol action.

Figure 1: An example multilayered telemetry system. Figure 2: DNP3 Secure Authentication using dynamic keys, that are updated, automatically and periodically, between a DNP3 Master and outstation RTU.

APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 7www.ProcessOnline.com.au

Telemetry

Diagnostic information for each I/O pointAnotherinherentfeatureoftheDNP3protocolisassociatingdiagnosticinformationforeachfield object - whether it’s pump status, tanklevel, current flow rate, etc.

Thediagnosticinformationanswersques-tions such as, is the point online or offline,was it locally forced, chatter-detected, hasit been restarted, is the value out of rangeandmuchmore.

Again,intypicalsystems,astatusindicationforapumpwillonlyshowitisONorOFF,inFAULT,orOK.ButwhenusingDNP3protocol,onecandetectiftheinformationregardingthestatusofthepumpiscomingfromthecorrectlocation.Thisisusefulbecause,remotely,onecantellifwiringiscorrect.AnotherexampleisifthechatterfilterbitisSET,thenifafielddeviceisgoingON/OFFcontinuously,spuriousevent logswill not becreated.

Communication to multiple mastersThisisaparticularlyusefulfeature,especiallyinwaterandwastewatersystems,sinceitistypical for a water or wastewater telemetrysystem to be spread over large areas. Thisis especially true in countries like the US,Australia,ChinaandBrazil.Whensystemsarespread over a large area, it is important forthe local operators of the telemetry systemto know what is happening, as it will allowthem to respond quickly. At the same time,the same data needs to be made availableat the system-wide, top-endDNP3master.

Advanced communications features for DNP3-based telemetry systemsAsstatedabove,oneofthecornerstonesofDNP3protocolisthatitisanopenprotocolwithnovendor-dependentvariations.AnyRTUthatclaimstosupportDNP3protocolmust adhere strictly to this rule.

However, the more capable and ad-vanced RTUs have managed to includeadditionalfeaturesthatdonotrelatetotheactualprotocolfeatures/propertiesorthemannerinwhichDNP3datainamessageis transferred. These additional featuresfocusonthecommunicationsitself,whichis, getting data from one location to an-other, effectively and efficiently.

• Peer-to-peer communications: Thisal lows for local communicationsbetween two DNP3 devices. If com-municationstoatop-endDNP3SCADAmasterislost,thenlocalRTUsystems(like a booster pump station andtank) can continue to operate withall data logged.

• DNP3 message pass-through: TheDNP3 protocol is primarily a point-to-pointprotocol.Point-to-point typecommunication architecture is notalwaysfeasibleinawaterandwaste-watertelemetrysystem.Assuch,themoreadvancedRTUshavetheabilityto receive a DNP3 message on oneport and resend via a second port,allowing for more advanced com-munication options.

• Data concentration: In a multilayeredtelemetrysystem,thereareinevitablygoing to be sub-master RTUs. DNP3does not have the ability to requestlocalandoutstationdatafromasingleRTU.Assuch,asubmasterRTUwouldhave the ability to map data receivedfrom an outstation DNP3 device toa new DNP3 object (address), whilemaintaining all of the original valuesand properties as provided by theoutstation RTU.

ConclusionDNP3 is a modern, robust, intelligent andtruly open protocol. While it has beenaroundforclosetotwodecadesnow,andthusatrulytriedandtestedprotocol, it isstillanevolvingprotocol.Thisisillustratedby the addition of secure authentication.

Awaterandwastewatertelemetrysys-temisacomplexsystemwithanumberofassetsandlocationstomonitorandcontrol.Fromacommunicationsperspective,itcanbeamultilayeredsystemusingavarietyofcommunicationsmediasuchasradio,cel-lular,PSTNandfibretointerconnectsites.

TheDNP3protocol,with itsmany fea-tures, helps enormously in implementingsuch a complex system and it does helpin reducing the complexity of a system.This in turn will help reduce operationaland maintenance costs for the end user.

CSE-Semaphore Pty Ltd

Contact info and more items like this at wf.net.au/M897

Figure 3: A DNP3 outstation device communicat-ing with several DNP3 master devices.

DNPAI0 IOPOINT_DClass 1, 32-bit analog input (variation 1) ai object, class 1, static var. 1 (With flags), event var. 3 (With time)

DNPAI1 IOPOINT_DClass 2, 32-bit analog input without flag (variation 3) ai object, class 2, static var. 3 (No flags), event var. 1 (No time)

DNPAI2 IOPOINT_D Class 0, 32-bit analog input (variation 1)

DNPAO0 IOPOINT_DClass 0, 32-bit analog output status (variation 1) analog output object, real time data point (class 0)

DNPBC0 IOPOINT_D Class 1, 32-bit binary counter (variation 1) binary input counter

DNPBI0 IOPOINT_BClass 1, binary input with status (variation 2) bi object, class 1, static var. 2 (Diagnostic flags), event var. 2 (With time)

DNPBI1 IOPOINT_B Class 0, single bit binary input (variation 1)

DNPBI2 IOPOINT_B Class 0, single bit binary input (variation 1)

DNPBO0 IOPOINT_BClass 3, binary output (variation 1) bo object, class 3; static var. 1 (With flags); event var. 1 (No time)

DNPFC0 IOPOINT_D Real time value (class 0), frozen counter 1

DNPFC1 IOPOINT_D

Table 1: Various DNP3 objects and their different classifications — 0, 1, 2 and 3.


NEWPRODUCTS

POE-POWERED PANEL PCThe Afolux AFL-057A is a 5.7″ Power over Ethernet (PoE) all-in-one

panel PC that integrates the low-power Intel Atom Z510/Z530 proces-

sor (up to 1.6 GHz), an LCD touch panel and PoE function into a

compact, fanless form factor.

The 5.7″ LCD panel is an LED backlit resistive touch screen that is

4-wire resistive touch capable. The panel PC also features a compact

flash slot, IP64 front panel protection from dust and spills, low power

consumption and a wide operating temperature of -20 to 60°C.

The AFL-057A is IEEE 802.3af compliant which eliminates the need

for AC outlets. The IEEE 802.3af PoE standard ensures that 12.95 W

of DC power is supplied to each connected device. PoE technology

allows the system to safely transfer power and data to remote devices

via the one cable (standard category 5e) within an ethernet network.

The high graphic performance of the Intel Z510P/Z530P 1.6 GHz processor supports full hardware

decoding for H.264, MPEG2, VC1 and WMV9. This eliminates the need for software decoding, therefore

avoiding the risk of overloading the processor. Multitasking is optimised with low CPU resource utilisation.

ICP Electronics Australia Pty Ltd

Contact info and more items like this at wf.net.au/P195

SAFETY LIGHT CURTAIN WITH INTEGRAL MUTINGThe Banner Engineering EZ-Screen low-profile safety light curtain with

integral muting is designed for use on smaller production machines.

The two-piece optoelectronic safeguarding device creates a screen

of synchronised, modulated infrared sensing beams that extend from

end-to-end of the housing - ensuring operators are completely pro-

tected from machine safety hazards. They are highly immune to EMI,

RFI, ambient light, weld flash and strobe lights, and come equipped

with factory burned-in emitter and receiver circuitry for toughness,

dependability and vibration tolerance.

The EZ-Screen LP with integral muting has a sensing range that

spans from 100 mm to 7 m. Offering seven different, predefined mut-

ing configuration options - including bypass, mute-dependent

override, mute enable and mute-cycle time extensions

for L-style cell exit application - the safety light

curtain suits diverse application requirements.

Capable of two or four mute device/sensor

hookup options, including a cost-effective, two-

sensor, X-pattern solution used for material entry and

exit applications and an L sensor solution that minimises the

floor space in manufacturing cell exit applications, the EZ-Screen

LP with integral muting provides enhanced application flexibility.

The optional CSM muting splitter cordset provides a complete

QD connectorised solution for a simple, low-cost installation.

Featuring a built-in muting function, the EZ-Screen safety light curtains do not require a third box,

which helps facilitate easy set-up, minimises wiring requirements and reduces installation costs. Set-up

can be performed without a PC, handheld programmer or other device; and DIP switch configuration

features many of the same functions as a standard EZ-Screen LP.

Micromax Pty Ltd


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Full infrared: Displays a full screen infrared view for maximum infrared detail.

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AutoBlend™ mode: Only Fluke has mastered the ability to blend partially-transparent infrared and digital images for easier problem detection.

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NEWPRODUCTS

MULTIFUNCTION FIELD CALIBRATORThe Beamex MC6 Advanced Field Calibrator and Communicator is one

device with five different operational modes, which means that it is

fast and easy to use, and users don’t have to carry multiple pieces of

equipment in the field. The operation modes include meter, calibrator,

documenting calibrator, data logger and fieldbus communicator. In ad-

dition, the MC6 communicates with Beamex CMX Calibration Software,

enabling fully automated and paperless calibration and documentation.

Developed from several years of market research and customer feedback,

the MC6 is an advanced, high-accuracy field calibrator and communicator that

offers calibration capabilities for pressure, temperature and various electrical

signals. It also contains a full fieldbus communicator for HART, FOUNDATION

Fieldbus and Profibus PA instruments.

Ease of use has been improved with a 5.7″ colour touch screen and mul-

tilingual user interface. The robust IP65-rated dust- and water-proof casing,

ergonomic design and light weight make it a suitable measurement device for

field use in various industries, such as pharmaceutical, energy, oil and gas, food

and beverage, service as well as the petrochemical and chemical industries.

Beamex is also introducing a new version of the CMX Calibration Software

that, together with the MC6, offers improved possibilities for paperless calibra-

tion management.

AMS Instrumentation & Calibration Pty Ltd


MULTIPARAMETER TRANSMITTER AND DISPLAYThe Signet 9900 SmartPro transmitter from GF Piping Systems

features multiparameter capabilities, flexible modularity and

an auto-sensing backlit display with ‘at-a-glance’ visibility,

even in dark conditions.

It provides a single channel interface for many different

parameters including flow, pH/ORP, conductivity/resistivity,

pressure, temperature, level, salinity and other sensor types

that output a 4-20 mA signal.

The large (9.9 x 9.9 cm) auto-sensing backlit display

allows visibility at a greater distance and large characters

reduce the risk of misreading or misinterpreting the dis-

played values. The display shows separate lines for units,

main and secondary measurements as well as a dial-type

digital bar graph.

Plug-in modules

enable the unit to

be adapted to meet

changing needs.

Optional modules

include relay, direct

conductivity/resistivity,

H Comm and a PC

Comm configuration

tool. The unit can

be used with default

values for quick and

easy programming or

can be customised with

labelling, adjustable minimum and maximum

bar graph settings, and unit and decimal measurement

choices. The device also allows third-party 4-20 mA signals

to be used as an input with an 8058 converter.

The 9900 is offered in both panel- or field-mount versions.

Both configurations can run on 12-32 VDC power (24 VDC

nominal). The 9900 can also be loop powered with compat-

ible sensors. Output accuracy is ±32 µA maximum error

at 25°C and 24 VDC with a resolution of 6 µA or better.

Standards and approvals include NEMA 4X/IP65, CE, UL

and China RoHS.

Georg Fischer Pty Ltd


http://www.datafactory.com.au

http://www.veederline.com.au

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Allen-Bradley® Micro800™ Family of PLCs Plug-in, customise and expand for seamless performance

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pH TRANSMITTERSRosemount Analytical 1066 transmitters are suitable for many industrial applications including those with

exacting performance requirements such as pharmaceutical and food and beverage and in harsh environ-

ments such as chemical plants, metals processing and effluent monitoring. The 1066

series supports HART 7 and is registered under the Interoperability Test Kit 6 (ITK6)

for FOUNDATION Fieldbus.

The Rosemount Analytical 1066 family of transmitters can measure pH, ORP, re-

sistivity/conductivity, percent concentration, total dissolved solids, total chlorine, free

chlorine, monochloramine, dissolved oxygen and dissolved ozone. A second sensor

input allows continuous pH correction for free chlorine measurement.

The instruments’ SMART capabilities also enable them to accept pre-calibrated

Rosemount Analytical SMART pH sensors, saving time and money for field technicians.

The 1066 Foundation Fieldbus transmitter can use analog output function blocks

to link to temperature and pressure measurements from the bus for temperature and

pressure compensation, which can increase the accuracy and responsiveness of the

measurement. The 1066 also has a full complement of analog control and math function

blocks, for use by the 1066 or other devices on the bus, to facilitate control in the field.

The HART version of the 1066 is switchable between HART 5 and 7, allowing the

1066 to be used with HART 7 capable hosts, as well as legacy hosts.

Housed in a 1/2 DIN enclosure, the 1066 series features a large display to provide ease of use and

an intuitive menu system. The 1066 is also compatible with the Emerson Smart Wireless THUM adapter.

Emerson Process Management

Contact info and more items like this at wf.net.au/N224

NEWPRODUCTS

APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 13

ETHERNET SWITCHESHirschmann RSP ethernet switches offer redundancy with zero switchover

time. They are designed for use in the field-level networks of power

supply companies, but they also can be used in any situation where

uninterrupted communication is required.

These robust fanless switches have eleven ports, three of which

can be used for SFP transceivers. They support Fast (100base-FX)

or - optionally - Gigabit ethernet (100/1000base-FX). The remaining

eight ports can be used

either for 100base-TX or

as a combination of four

SFP transceivers and four

TX ports.

Addi t ional features

include comprehensive

management, diagnostic

and filter functions plus

a variety of redundancy

methods and expanded

security mechanisms.

In addi t ion to the

standard configuration,

Hirschmann also offers a version that supports highly precise synchro-

nisation compliant with IEEE 1588v2, plus PRP (Parallel Redundancy

Protocol) and HSR (High-availability Seamless Redundancy). This means

that it is possible to implement networks that guarantee uninterrupted

data communications with the attached systems and can thus - in the

case of the electricity supply industry - guarantee reliable power sup-

plies to end customers at all times.

These switches have high vibration resistance and extensive resilience

to magnetic fields and electrostatic discharges. Redundancy methods

such as PRP, HSR and PRP/HSR Redundancy Box, RSTP, MRP and

Fast MRP ensure a high level of network availability.

Mounted on DIN rails, the switches can easily be activated by plug-

and-play and feature sturdy, compact stainless steel housings measuring

100W x 164H x 116D mm.

Belden Australia Pty Ltd


NEWPRODUCTS

PROGRAMMABLE STEPPER DRIVESRTA has launched three models of stepper drives that

incorporate motion controllers and range from 24 VDC

to 240 VAC supply. In many cases, this eliminates the

need for a separate motion controller, reducing the

cost and size of the system. An added advantage

is that the programming language used is specially

designed for motion control rather than the standard

PLC-based languages.

Several motion programs can be loaded into the

drive and stored. A program is selected using dedi-

cated inputs in BCD and run using a Start input. The

drives run standalone so it is not necessary to have

a computer or PLC connected at all times. The drives

also have several digital I/Os, a datum switch input

and emergency stop input.

For multiaxis machines, up to 48 drives can be

linked on a single serial line. Several instructions are

available such as indexed run with or without ramp,

free run with or without ramp, run with programmable

braking distance, time delays, conditional

jump, For/Next loop and programming in

absolute or relative coordinates. Some

drives have an optional analog speed

control via an external potentiometer

or an analog DC voltage.

Automated Motion Systems Pty Ltd


http://www.beamex.com


HOT PRODUCTSON WWW.PROCESSONLINE.COM.AU THIS MONTH

>

>

>

LEVEL DETECTOR FOR SOLIDSThe FTI77 is a compact capacitive

point level transmitter that can be

used for point level detection at high

temperatures in bulk solids and can

be operated in minimum or maximum

failsafe mode.

Endress+Hauser Australia Pty Ltd

WF.NET.AU/N268

STAINLESS STEEL PANEL PCThe IPPC-8151S is a fanless industrial

panel PC with a 15″ XGA TFT LCD,

an Intel Celeron-M 1 GHz CPU, and a

chemical-resistant touchscreen.

Advantech Australia Pty Ltd

WF.NET.AU/N333

ENCODER SIGNAL EXPANDERSMotrona’s encoder signal expanders are

rail-mounted modules designed to take

the signals from one incremental square

wave output encoder and expand it to two

or more encoders.

Plant Control & Automation

WF.NET.AU/N270

INFRARED THERMOMETERSThe Ircon Modline 7 Series infrared thermom-

eter is a rugged, IP65 sealed sensor system

for continuous temperature monitoring up

to 3000°C.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/N095

PRESSURE SWITCHThe PSD-31 pressure switch has a flush

diaphragm to help eliminate clogging of

the pressure channel and prevent possible

contamination of the process.

WIKA Australia

WF.NET.AU/N115

>

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http://www.gardnerdenver.com.au


Check out this magazine’s sister website.

INCLINOMETERSFraba Posital has introduced industrial and heavy-duty versions of its Accelens (ACS)

inclinometers, featuring either a plastic or aluminium housing. In many applications, these

non-contact sensors can be used as an alternative to rotary encoders. The units feature

capacitive sensor cells based on MEMS technology (microelectromechanical systems)

and allow users to measure inclination values directly, requiring no mechanical coupling

to drive elements. Mounting fixtures and couplings are therefore rendered unnecessary,

minimising the constructive effort compared with other solutions.

The inclinometers are available as single-axis models with a 360° measuring range

and as double-axis models with a ±80° measuring range. They provide a 0.01° resolu-

tion at a 0.1° measuring accuracy. A high sampling rate of up to 100 measurements/s

enables an efficient filtering of vibrations and shocks and minimises the settling time.

Depending on the model, the robust devices provide IP68 or IP69K protection. They are

available with SSI, CANopen, DeviceNet or fieldbus interfaces and with analog voltage

or current outputs. Designed for a wide temperature range (-40 to +85°C), they can be

used under extreme environmental conditions, such as in mobile machinery.

Plant Control & Automation


THREE-PHASE POWER QUALITY ANALYSERSThe Fluke 430 Series II three-phase power quality analys-

ers are designed to help facilities reduce electrical power

consumption and improve the performance and lifespan

of electromechanical equipment by providing the return

on investment (ROI) justification to mitigate power quality

distortion.

With the Unified Power function of the 430 Series II,

electricians, utility technicians, electrical engineers, field

service technicians and energy consultants can now have

the ability to automatically quantify the energy wasted by

harmonics and unbalance; and by inputting the utility rate

structure, the user can even calculate the monetary cost

of the wasted energy.

While these new models consume less energy as individual installations, they increase the level of power quality

disturbance in the overall electrical system, increasing waste energy due to harmonics and reducing the total potential

energy savings. The Fluke 430 Series II calculates the monetary cost of that waste energy.

The Series II models have up to 32 GB (8 GB standard) memory, a swappable SD memory card and USB

connectivity for longer power, energy logging and faster data download. Screen quality and battery life are both

improved and the accompanying software has been redesigned to give users more options to analyse both

power quality and power consumption. Both models are fully compliant with the IEC 61000-4-30 Class-A stand-

ard. Each one can monitor systems with up to 10 power quality parameters on one screen and can record up to

150 parameters on four phases simultaneously, in accordance with the EN50160 standard, and are safety rated

600 V CAT IV/1000 V CAT III.

Fluke Australia Pty Ltd


NEWPRODUCTS

http://www.sew-eurodrive.com.au


Variable speed drive (VSD) manufacturers are in thevanguardofthedevelopmentof intelligentdevices.Thefunctionality being demanded from VSDs is manifoldand includes enhanced connectivity, reduced energy

consumption, minimised downtime and features that intelligentlyreact to, as well as prevent, real problems, preferably beforethey cause damage.

The growing use of VSDs, particularly intelligent drives forpump control, represents a major departure from the standardoperatingpracticeofusingcontrolvalvestovaryfluidflow.Withits low energy usage and low maintenance outlay, the total lifecyclecostofaVSD-controlledpumpingsystemcanbesignificantlylessthantraditionalpumptechnology.OtherVSDbenefitsincludesmootherstart-upsandproductionchanges,moreprecisecontrolduring continuous operation and faster diagnosis of potentialsystem problems before product quality or process operation isnegatively affected.

Theemergenceofintelligentpumpsisacriticalstepforwardintheevolutionofprocessmanagement.Withembeddedintelligence,VSDscanprovidepumpcontrol,pumpconditionmonitoring,protectionandtraditionalenergy-savingbenefits.Figure 1showsasummaryofthebenefitsofVSDsatthevariousoperatingpointsofamotor.

Pump cleaningConsider, for instance, the antijam or antiragging function nowfound in several VSDs. A long-standing problem suffered bywater companies is that of ‘ragging’, the fouling of pump impel-

lers which consumes thousands of hours of maintenance timein sewage pumping stations and wastewater treatment plantsaround the world. Manually clearing the problem is a costly andunpleasant task requiring a maintenance team and frequently acrane. Downtime may extend to several days, during which timethebackupsystemsareunderadditionalpressure.Atotalsystemfailure can result in effluent leakage, which has environmentand human health implications as well as clean-up costs andlegislation issues.

Theantijamfunctionpreventspumpsandpipesfromcloggingbyinitiatingasequenceofforwardandreverserunsofthepumpto clean the impeller.

Dedicated drives for pumpsBut it is not just by unclogging impellers that the latest intel-ligent drive technology can enhance a pump’s life cycle. In fact,thereareseveralpump-specificrequirementsthatcanbebundledinto the functionality of the drive module that can make a drivespecific for water and wastewater applications.

The idea of application-specific drives is something whichIMSResearch,a leadingsupplierofmarket research,has identi-fied as a growing trend. With such drives, the user can reducetheir total cost through shorter start-up times, lower integrationcostsandimprovedmachineproductivity.IMSResearchestimatesthat low-voltage AC drive shipments to the global water andwastewater market will grow from US$448 million in 2010 toUS$760 million in 2014.

CLEVERPUMPINGSanna-Kaisa Ehanto, ABB Drives, Helsinki, Finland

Climate change, increasing water demandsdue to global urbanisation and regulatoryobligations are all making the water sectoran attractive arena for technologies thatcan help reduce costs and contribute toreducing the effects of climate change. Itis against this backdrop that the demandfor intelligent process control equipment issurging throughout the water industry.

APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 19

Pumps are by far the biggest application area for variablespeed drives. And all these pumps have specific requirementsfromflowcalculationthroughtolevelcontrol,allofwhichcanbesolvedusingthelatestsoftwarenowavailable.Thedrives’pump-specific functions decrease the life cycle cost of the pumpingsystems,helpingtosavetimeandmoney,boostenergyefficiencyand reduce carbon dioxide emissions.

Typical of the applications which can now benefit from intel-ligent pump control are water pumping stations, many of whichdemand,inadditiontotheantijamfeaturementionedabove, levelcontrol and pump priority functions.

Level controlLevel control is designed to control the filling or emptying ofstoragetankscontainingwastewaterorstormwatercontaminatedwith dirt, gravel, litter and other debris. The function seeks topreventsedimentbuild-uponthetankwallsbyrandomlyvaryingthe surface levelwithin a preset range.Additionally, aggressive,fast-rampstartingcreatesaflusheffect,therebypreventingblock-ages, while minimising energy consumption by running pumpswithin a favourable operating area.

Pump priorityPump priority schedules pump operation to enable maintenanceplanning. It is intended for systems where the consumption ratevaries with demand. For example, the drive can be programmedtooperatehighercapacitypumpsduringthedaytimeandsmaller

units at night. This allows for better maintenance planning andcan boost energy efficiency by operating pumps closer to theirbest-efficiency point.

Energy savingEnergysaving liesat theheartofVSDuse inpumpingsystems.

In general, the life cycle costs of a pump system depend onthepowerrangeanditsin-servicelifetime.However,typicalcostsforpumpsystemsbetween50to100kWwillbeincurredthroughenergy usage (between 70-80%) and maintenance (20-30%).

Overa20-yearperiod,thecombinedenergyandmaintenancecostsmayexceed10timestheinitialpumppurchaseprice.Theseoperating costs can be dramatically reduced through efficiencyimprovements.

Two common causes of pump system efficiency loss arepump oversizing and throttled valves. Poor pump performancecanresult indowntime,collateraldamagetoequipmentandhighmaintenance costs.

In VSD-controlled pumping systems it is also possible to runthe pump at higher than nominal rotational speeds. Normally,the motor is designed so that it enables operation in the areaof higher power range. This makes it possible to run the sameVSD-controlled pump in a higher power range area comparedto an on-off controlled pump. This mode of operation enables apumpwithasmallerpowerratingtobeused,whichalsoreducesinitial investment cost.This isvalid for situations inwhichpeakflows occur every now and then (see Figure 2).

The energy-saving benefits of VSDs are well documented,with savings typically from 20 to 60% readily achievable inspeed-controlled pump applications. Now, as part of the addedintelligence within a drive, manufacturers are including featuressuch as energy optimisation, which improves the total energyefficiency of the pumping system.

Trackingthisentireenergysaving ispossiblethrough in-builtenergycountersthatshowhowmuchenergyhasbeenusedandsaved in kWh, currency or volume of CO2 emissions.

Pressure and flow controlUsing VSDs to control pressure and flow improves flow man-agement, minimises maintenance and reduces electrical energyrequirements.

Apressureboostingstation,forexample,feedswaterdirectlyinto the distribution system and seeks to maintain a constantpressure in the pipes. With smooth VSD control there are nopressureshockscausingnoise,erosionorleakageinthepipeline.

IntelligentVSDsalsoincreaseuptime:paralleldrivesenablethesystemtorunwith100%redundancy.Ifadefectoccursinoneofthepumps,motorsordrives,theotherswillcontinueoperationwithoutany interruption. Pump stations are sometimes located remotely

Motors&drives


andserviceactivitiesmighttakesometime.Withredundancy,thepump station operation is trouble free with minimised downtime.

Further, the running timeof the pumps can be controlledwiththe pump priority function (see earlier) to ensure that wear andtear on all pumps is the same.

Where several parallel pumps are operated together and therequiredflowrate isvariable, a functioncalledmultipumpcontrolmaintains stable process conditions optimising the speed andnumber of the pumps needed. This function provides the mostenergy-efficient way to operate parallel pumps.

Sleep and boostAnother pressure-related function is that of sleep and boost.

Traditionally,standardPIDcontrolmayallowapumptooperateatundesirably lowspeedsforprolongedperiodsoftime.Thiscancause mechanical issues with certain pump types and in generalwastesenergy,sincemostpumpsdonotgeneratesignificantflowat low speeds.

Asleepandboostfunction,however,letsthedrivegoto‘sleep’,meaningthatthedriveoutputwillshutoffandthepumpwillstop.Thisissuitableforcleanwaterpumpingsystemsduringnight-timewhenwaterconsumptionfalls.Ifthesystempressuredropsbelowa defined level, this function detects slow rotation and runs thepump to boost the pressure in the pipeline or water level in thetank prior to shutdown. This extends the pump’s sleep time andtherefore saves energy. The pressure is continuously monitoredandpumpingrestartswhenthepressurefallsbelowtheminimumlevel. It also avoids unnecessary starting and stopping and helpsto flush the pipelines.

Flow calculationAnotherfeaturenowbuiltintodrivesisflowcalculation.Thisfunc-tionprovides thedrivewithaflowmeter routine thatenables the

pumpedvolumetobemonitoredbytheVSD,withoutanyadditionalcomponents.Thisisausefulfeatureinsystemswheredataaboutthe total flow during a specific time period is needed.

Remote monitoringSome drives can connect to major automation systems via anethernet connection or GSM wireless network. This is achievedwith a dedicated gateway concept between the fieldbus systemsand the drives. A remote monitoring module gives simple accessto the drive via the internet, communicating via a standard webbrowser.Theusercansetupavirtualmonitoringroomwhereverthere is a PC with an internet connection or via a simple dial-upmodemconnection.Thisenablesremotemonitoring,configuration,diagnostics and, when needed, control.

Remote monitoring provides easy access to pumping systems,eveninfarawaylocations,therebyavoidingunnecessarysitevisitsand saving time. Through the use of ethernet adapters, processdata, logs and event messages concerning pumpedvolumes, tanklevels and other operating conditions can be sent independently.

SummaryDrive modules specially designed for water and wastewater ap-plicationscansignificantlyenhanceapump’slifecycle.Withupto60% energy savings possible along with reduced carbon dioxideemissionsandpaybackon investmentoftenwithin twoyears, thefuture for the intelligent variable speed drive is certainly lookingbright.

ABB Australia Pty Ltd


Figure 2: Power consumption for various control methods.Figure 1: Summary of a VSD’s benefits at various motor operating points.

Motors&drives

http://www.krohne.com


Check out this magazine’s sister website.

COMPACT SWITCHES

The managed switches from Phoenix Contact’s Factory Line range have been

expanded to include several types of switches that are preset for EtherNet/IP.

These compact switches feature IGMP snooping and multicast detection func-

tions that are activated upon shipment, enabling the switches to be integrated

with minimal configuration into EtherNet/IP applications.

With the version 3.40 firmware, the switches have the Auto Query Port expan-

sion, which allows fast forwarding of EtherNet/IP telegrams after a redundancy

toggle. The switch configuration can also now be saved on an external PC.

The version 3.40 firmware is available immediately for download.

Phoenix Contact Pty Ltd


HIGH-TEMPERATURE PRESSURE TRANSMITTERThe Series 35X HTC high-temperature pressure transmitter

from Keller is primarily designed for biotechnology and food

industry applications. The pressure of hot media applied

to the diaphragm is transferred via an exposed oil-filled

spiral capillary to the sensing element. Heat to a maximum

of 300°C is therefore safely dissipated to the atmosphere

before it reaches the sensing element when the sensor is

optimally mounted.

The 35X HTC is based on the existing Series 30 digitally

compensated pressure transmitter range. The 35X HTC is

available in ranges from -1 to 3 to 0 to 1000 bar. While the

linearity (BSl) is 0.05%FS, the combined error is 0.5%FS for

the entire operating temperature band from 20 to 300°C.

The frequency response is 100 Hz. Both analog and digital

output signals are standard, including RS485, 0-10 V and

4-20 mA. It is possible to use both digital and analog signals

concurrently. Supply voltage is 8-28 VDC for the RS485 and

4-20 mA outputs. The 0-10 V signal requires 12-30 VDC input.

Several choices of interface cables are available within

the Keller product range to communicate between the

35X HTC and a PC. PROG30 PC-compatible software is

available to set up and calibrate the Series 35X HTC, to

rescale it from 100% down to 30% FS, to adjust the zero,

change the measurement unit and enable several other

functions. READ30 data acquisition software is also available

to facilitate various graphical presentations, as well as to

monitor up to 16 transmitters on the one serial connection.

Bestech Australia Pty Ltd


pH SENSORThe Rosemount Analytical Model RB pH sensor

is designed for optimum sensor life in demanding

scrubber applications.

pH sensors are most vulnerable to failure due to

poisoning of the reference junction. The RB sensor

features a proprietary multijunction that hinders refer-

ence poisoning. This design is particularly successful against aggressive sulfides found in scrubbers.

The unique multijunction reference chamber of the RB extends survivability. In addition, the sensor

is built of chemically resistant Kynar, adding to its long life.

Instead of replacing the entire sensor, the Model RB sensor can be reassembled inside its titanium

sheath, high-pressure body, reducing costs for replacement and shipping.

The sensor allows for optional installation methods including inline, submerged or ball-valve insertion.

Emerson Process Management


NEWPRODUCTS

BUY DIRECT AND SAVEEVERYDAY LOW PRICESSAME-DAY SHIPPINGSATISFIED CUSTOMERSOVER 9,500 PRODUCTS!Complete up-to-date downloadable pricelists in PDFformat is always available online.Click on to link directly to our online store for pricing,and ordering details.It’s all online 24/7 at our main Web site.You can purchase products, get specs, compareprices, get a product overview or deep product info,watch product videos, and much, much more.

WHAT’S UP WITH AUTOMATIONDIRECT

Looking for a common senseway to buy industrial controls?

It's time to try AUTOMATIONDIRECT

Order Today, Ships Today!More than just a great online store In addition to ourmain Web site, www.automationdirect.com.au,we have a whole network of support sites to help you quicklyand efficiently choose and use the automation products youneed.In addition to our DVD catalog, we have an online network ofinformation available 24/7.FREE videos, FREE software, FREE documentation, FREE support,FREE magazine . . . . . . well you get the point. :-)

Automation Direct Pty LtdAsia and Pacific RegionAustralia Wide: 1-800-6330405New Zealand: 0-800-6330405Asia Pacific: 61-7-55874222Email: [email protected]: 61-7-55252053

www.automationdirect.com.au

Online Store - available 24/7

How do I shop for the parts I need?When you’re ready to browse or choose parts in the store, Just -choose parts from layout similar to the picture below, put in theqty and hit add to cart and select other items or “click here tocheck out”Open an account if you dont already have one, please remem-ber your user name etc, during CHECKOUT of your first orderand just fill in your details and your address details for futureordering.You may order using Company Purchase Orders, Credit Card,Direct Debit or Cheque.We accept approved Customer Purchase Orders, our terms arenett 30 days and also major credit cards (MasterCard, VISA). To establish a credit account with AUTOMATIONDIRECT, you canprint our credit application from the Web site and fax or email itback to us to get the process started.

wnipemarch12_WNIPE 8/03/2012 8:11 AM Page 1


NEWPRODUCTS

IN-PROCESS SPECTROPHOTOMETERSCarl Zeiss offers a wide range

of spectrophotometer modules

for sensitive multichannel inline,

online and at-line measurements.

The MMS family of miniature

spectrometer modules with CCD

detectors enable simultaneous

high-precision colour measure-

ments in up to four wavelengths

on a single system for the spectral

range between 350 and 950 nm.

Compact MMS modules can

be used to accurately conduct

content analyses, monitor layer

thickness or mixture homogeneity,

inspect extrusion processes and

perform colour measurements at

any point in the manufacturing

process.

The family of MMS CCD mod-

ules feature high sensitivity and

can be configured for a wide range

of industries including plastics,

chemical and pharmaceutical

manufacturing, agriculture or food.

With the family of MMS CCD

modules, the company also now

offers OEM spectrometer modules

with integrated electronics unit.

Carl Zeiss Pty Ltd


DUAL BULK BAG FILLING SYSTEMThe Dual Bulk Bag Filling System from Flexicon integrates two Swing-Down bulk bag fillers with a

Flexicon Pallet Dispenser and powered roller conveyors, allowing safe, high-capacity filling of bulk bags

of all popular sizes. Programmable controls allow the fillers to operate separately or simultaneously,

filling bags of the same size or two different sizes.

When a filling cycle is initi-

ated by push-button or contact

closure, pallet dispenser forks

lower the stack of pallets onto

the roller conveyor, withdraw

from the bottom pallet and

raise the remaining pallets,

allowing the roller conveyor

equipped with photoelectric

sensors to move the dis-

pensed pallet into position

below the filling station.

The bag connection frame

of the Swing-Down fill head

allows an operator at floor

level to safely and quickly at-

tach bag straps to automated

latches, slide the bag spout over an inflatable spout seal and press a spout seal inflation button.

The system then automatically pivots the bag connection frame back to horizontal, raises the entire

fill head, inflates the bag to remove creases, fills the bag at a high rate, finishes filling accurately at

trickle-feed rate, deflates the spout seal, releases the bag loops, raises the fill head to disengage the

spout, rolls the bag out of the filling area, and rolls a new pallet into place to begin another cycle.

The system is offered with the company's own mechanical or pneumatic material delivery system

integrated with the user's upstream process equipment or other material source.

Flexicon Corporation (Australia) Pty Limited


http://www.techrentals.com.au


NEWPRODUCTS

FIELD-INSTALLABLE RJ45 PLUGH a r t i n g

has released

a range of high-

speed 8-pole RJ45 con-

nectors. The RJ Industrial 10G

is an upgrade of Harting’s RJ45

connector that requires no tools for con-

nection and features a future-proof design

for 10 gigabit ethernet.

The connection is made reliably and quickly using

insulation displacement terminal technology. The insulation

displacement terminals are designed for rigid and flexible

conductors with a broad range of wire cross-sections.

Cables with diameters from 4.5 to 9 mm are securely fixed

in place in the connector with a newly developed cable gland.

This allows users to connect all customary ethernet cable

types with this one RJ45 connector type.

Due to a compact design, the rugged IP 20 model is also

suitable for multiport RJ45 jacks. In addition to the IP20

models, all known IP65/67 PushPull types up to Han 3A are

now available with this insert.

Soanar Limited


PRESSURE GAUGEWIKA has expanded its offer of

digital pressure gauges with

the model CPG500 that

offers a high degree of

measuring accuracy

and speed.

A digital pressure

gauge combines the

accuracy of digital

technology with the

simplicity of an analog

pressure measuring instru-

ment. Given its very high sampling

rate of 100 measurements/s, the

CPG500 is suitable for capturing fast

pressure peaks and drops. It also oper-

ates with a high accuracy of 0.25% of span, and

can be used both for pure pressure measurement and

for the calibration of most analog pressure gauges.

With its robust case and its simple, four-button

operation, the CPG500 is a cost-effective alternative to

the model CPG1000 precision digital pressure gauge.

WIKA Australia


http://www.advantech.net.au

26 WHAT'S NEW IN PROCESS TECHNOLOGY - APRIL 2012 www.ProcessOnline.com.au

UPGRADED PROCESS AUTOMATION SYSTEMRockwell Automation has extended the reach of its PlantPAx process

automation system to integrate critical rotating assets such as com-

pressors, pumps, turbines and fans, giving users the ability to manage

plant-wide operations with a single platform. The system combines

the company's core process automation capabilities and technologies

with those of partners and acquisitions to deliver an integrated control

and information solution.

Users can now tie intelligent motor devices into this unified-control

architecture, making an immediate and measurable impact on asset

availability, operational efficiency and energy management. The tight

integration between process automation and motor control is especially

beneficial in heavy industrial applications with considerable mechani-

cal investments, such as metals, mining, cement, power, oil and gas,

water/wastewater, and pulp and paper applications.

Users will have access to diagnostic information on any device

in the system from any location - including motor control centres,

drives, compressors, pumps, fans and instrumentation. Leveraging the

EtherNet/IP network, engineers can monitor process conditions such as

electric motor current, vibration signatures of key rotating assets and

torque signatures of variable speed drives. This allows plant engineers

to predict potential problems and help avoid equipment downtime -

resulting in improved productivity and reduced maintenance costs.

Other key features with the system include EtherNet/IP network

support for redundant systems and device-level ring network topol-

ogy that provides a highly available EtherNet/IP network without any

additional infrastructure costs; improved device integration and asset

management; and accelerated design engineering.

Rockwell Automation Australia


NEWPRODUCTS

All the Tools You Need for Embedded

Measurements and Control,in one rugged box.

>> To learn more about CompactRIO, visit ni.com/compactRIO 1800 300 800

©2012 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments,NI, and ni.com are trademarks of National Instruments.Other product and company names listed are trademarks or trade names of their respective companies. 05309

■ Graphical Software

■ Sensor Connectivity

■ Signal Analysis

■ Control Algorithms

■ Custom Timing

■ Custom Triggering

■ Actuator Connectivity

■ Embedded Storage

■ Industrial Networks

■ Expansion Systems

The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution. The range of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the benefits of customization with the convenience of an off-the-shelf platform.

RS485 INPUT SAFETY BARRIERThe Mornsun TD100-EX-485 is a DIN

rail-mounting, RS485 half-duplex digital

output safety barrier.

The detection side isolated safety

barrier can supply isolated DC power from

the transmitters in the security zone to the danger zone, transform the

RS485 digital signal of the danger zone into isolated RS485 or RS232

with digital signal transmission to the security zone while increasing

the anti-jamming capability of the industrial production process control

system, to ensure system stability and reliability.

Only one independent power supply is required, 18-32 VDC. The

series has 3-port isolation (input, output and power supply) with a

high isolation voltage of 2500 VAC and MTBF claimed to be greater

than 500,000 hours.

Three coloured LEDs indicate status for power on, transmitting and

receiving. These devices meet IEC/EN61326 standards with safety

class IP20 (IEC60529/EN60529).

DLPC Pty Ltd


http://www.ni.com/compactrio


Wireless and battery-less pushbuttonsSignificantly reduce your installation time and achieve cost savings of at least 20 per cent

Harmony Ø22mm XB4 Metal and XB5 Plastic Pushbuttons

Harmony Ø22mm Fingerprint Recognition Biometric Switch

Discover more

www.schneider-electric.com.au | Call 1300 369 233© 2012 Schneider Electric. All Rights Reserved. CLIPCOM24379

Use our FREE calculator to determine the time and cost savings for your application using Harmony XB5R pushbuttons!Simply visit www.SEReply.com and enter key code 52494K

Maximise efficiency with Harmony XB5R wireless and battery-less pushbuttons.

> Increase flexibility and freedom of movement

> Control your plant operation over distances of up to 100m

> No battery to replace, recharge or recycle

> Quick and easy to install with wireless technology

Give yourself a competitive edge… Increase the productivity of your people and equipment.

ACTIVE HARMONIC FILTERSAcF series active filters from Maschinenfabrik Reinhausen (MR) are suitable for three-

phase, 3-wire and three-phase, 4-wire systems and are available both in 415 and

690 V versions.

The AcF series active filter uses a special T-sine reconstruction filter between the

network and the IGBTs in each module in order to provide a significantly lower switch-

ing frequency, thereby minimising losses and maximising the lifetime of IGBTs. They are

available in current ranges from 100 to 600 A and up to 4800 A in parallel.

They have a low power loss of 1900 W per 100 A module, and offer both global and

selective harmonic compensation to the 50th harmonic and a response time of 1 ms

compared to, typically, 20 ms for other active filters.

The AcF series active filter has a unitised and modular construction, and an embed-

ded web server means that no special software is necessary.

Both open-loop and closed-loop configuration is possible. The closed-loop configura-

tion is used to comply with the THID injected into the grid. The open-loop control is

used to provide compensation for an individual or a group of nonlinear loads inside

the plant facility.

The active filters can also be used for MV compensation via an interposing transformer.

In this capacity the filters are employed in three-phase, 3-wire sub-distribution networks.

Westek Electronics Pty Ltd


NEWPRODUCTS


NEWPRODUCTS

OPTIC FIBRE TESTERThe Fluke OptiFiber Pro OTDR is an optical time-domain reflectometer (OTDR)

with a smartphone interface. The smartphone interface supports gesture-based

commands and technology enhancements that simplify testing in data centre

environments, minimising the learning curve typically associated with older OTDRs

by greatly reducing complexity.

A simplified ‘datacentre mode’ automates the process of setting test parameters,

like wavelength or end-detection algorithms, significantly reducing the set-up time

and the complexity of learning how to troubleshoot data centre problems.

With a short event and attenuation dead zones, it is capable of testing connectors

and patch cords as short as 0.5 m. This is critical in virtualised server environments,

where connections are often less than 1 m and hidden performance issues can

severely decrease the reliability of data centres.

Through visual fault presentation the OptiFiber Pro shows all fibre events graphi-

cally letting any user quickly and easily interpret OTDR trace results, and built-in

project management tools facilitate the assignment and tracking of fibre testing

projects for multiple users, increasing efficiency, enhancing project tracking visibility

and enabling cost-effective device sharing.

Upgraded LinkWare management software helps simplify workflow management,

integrates test results and keeps the OTDR up to date with the latest software.

Fluke Australia Pty Ltd



NEWPRODUCTS

PRESSURE SWITCH WITH FLUSH DIAPHRAGMFor industrial processes with critical media, WIKA has expanded its range of

electronic pressure switches with the PSD-31 with flush diaphragm.

The instrument is suitable for application in abrasive, aggressive, adhesive,

crystalline and viscous media. Its flush connection eliminates any clogging of

the pressure channel with particles and also prevents possible contamination

of the process.

Technically, the new pressure switch is the same as the PSD-30. Due to its

small size and the ability to rotate both the display and connection, it offers

mounting flexibility. Its simple menu structure (in accordance with the VDMA

standard) enables quick and easy operation, while a large LED display provides

high readability. The switch is available in several country-specific versions, for use

worldwide. Its quality and safety are documented by its cULus listing.

WIKA Australia


THERMAL IMAGING CAMERAAn addition to FLIR Systems’

E-Series range, the FLIR E30

thermal imaging camera is suit-

able for electrical and mechanical

maintenance inspections.

The E30 has a 2 MP visual

camera that enables the operator

to reference the position of the

identified problem with a visual

image. The thermal and visual

images are stored simultaneously

by pressing a button.

For darker environments, an

LED lamp at the front of the

camera may help ensure good-

quality images are captured. As

with all the E-Series range, the

E30 has a laser pointer to help

the user associate the hot spot

on the thermal image with the

real physical target in the field.

An uncooled vanadium ox-

ide microbolometer detector

produces clear thermal images

of 160 x 120 pixels, allowing

temperature differences as low

as 0.1°C to become visible. The

camera measures temperatures

from -20 to +350°C.

The rugged outer casing protects

the inner core and is IP54 rated.

The 3.4" LCD touch screen shows

thermal images and allows users to

access all camera features.

Cameras from the FLIR E-Series

come with FLIR Tools software,

which imports thermal images

from the camera to a PC and al-

lows users to control layout, move

images and resize measurement

tools. It creates PDF imagesheets

of specific images; adds headers,

footers and logos to reports; and

applies filters when searching for

images. Users that require more

reporting functionalities can select

FLIR Reporter software, which is

also compatible with the E-Series

cameras.

FLIR Systems Australia Pty Ltd


http://www.georgfischer.com.au

zone sponsor zone partner media partner

Making Air Technology

http://www.nationalmanufacturingweek.com.au


Reliable pallet labelling for CUB

Carlton&UnitedBreweries(CUB),Australia’slargest brewer, operates five breweries inAustralia as well as breweries in Fiji andSamoa. ItsYatalaBrewery inQueensland isone of the most state-of-the-art breweriesintheworld,producing450million litresofbeereachyear.

With Yatala’s advanced brewing andpackaging technology, there is no room forinaccurate,incompleteorillegiblepalletlabelsthatslowoutputandraiseproductioncosts.Australia’s major retailers require logisticslabelswithunique serial shipping containercodes (SSCCs) to be applied to palletsdeliveredtotheirdistributioncentressotheycanbescannedonreceipt.

Toensuretheproductionlinecontinuedtomeet industry standards for pallet labelling,CUBneededatime-savingandrobustsolutionthat could withstand a 24/7 productionschedule.Thesolutionalsoneededtoapplylabelsatmultipleheightswhilecomplyingwithtrading partner requirements, including theGS1barcodingstandardsforpalletlabelling.

Working closely with CUB personal,insignia, a strategic alliance partner of GS1Australia, developed the Domino print-and-applylabelapplicatorsystem.

Theapplicatorsitswithinasealedcabinetwithapneumaticdoorthatopensonlywhenalabelistobeapplied.Thecabinetisdesignedto keep dust out, providing the DominoM-Seriesprinterwithanoptimumoperatingenvironment.Thisensurestheprinterandtheprintheadarenotdegradedbydustandothermaterialscommonlyfoundinwarehouseandproduction environments. A fully functionalprint head is vital for printing barcodes toGS1standards.

Thepallet applicatoratCUBcomeswitha standard check-scanner feature mountedtothetamppad.Thisunit isprotectedviaasensor system to ensure it is not damagedduringoperation.Thecheckscannerscansthebarcodeonthelabeltoensurethatitisappliedcorrectlyandthebarcodeisreadable.ItthenverifiesthatthecorrectlabelandrelatedGTINandSSCCareappliedtothecorrectpalletandinthecorrectposition.

TheDominoM-Seriesprintengineoperateswitha300dpiprinthead.Thishigh-resolutionprint head provides more options for themaximummagnificationofthebarcodeswithinthestandardsforthespecificlabelsizeused.Thescannermonitorstheperformanceoftheprint headand thequality of theprint head,andthemediamanagementoftheprintengineensures a quality barcode is producedevenwhenprintingabarcodeinladderformat.Thishasallowedinsigniatodeploya4″300dpiprintheadatCUBandprintthelabelinladderformat.

Unique tamp-pad and tamp-arm cylindertechnologywithinthesystemallowsthelabeltobe rotated90°onceon the tamppadandappliedinthecorrectorientationtothepallet.Thismeansthatifapixelintheprintheadblowsandalineiscreatedintheprint,itwillnotleadtoanunreadablebarcodeasitwillcutacrossthebarcodebarsleavingalegiblebarcode.

Akeyfeatureofthepallet-labellingsystemdeveloped for CUB is its automatic heightadjustment capability.CUBhas a coreneedtomeetanindustryrequirementofapplyingaGS1logisticslabeltounwrappedpallets.Inthiscasetheyneedtoapplythelabeltothesideofonecartononlyonthepallet-inotherwords,not overlapping anothercarton.TheDominoM-Series SSCC pallet-labelling system’sautomaticheight-adjustmenttechnologymeans

thatoncealabelisprintedontothetamppad,thetamparmwillthendroptotherequiredheightforthespecificpalletconfigurationfortheproductonthepalletandapplythelabeltoasinglecarton.Asonlythelightweighttamparmismovingtomeetthesedifferingheightrequirements,thereis lesswearonthesystemandthearmcanmovequicklytoapplythelabelintheshortesttimepossible.Thisfeaturecanalsobeusedtoapplylabelstopartpalletswithinanoperation.WiththissysteminplacethelabelisappliedinthecorrectpositionaccordingtoGS1standardssothepalletcanbescannedonreceiptattheretailers’distributioncentres.

As a proactive business, CUB saw thepotentialsupplychainbenefitsofimplementingthissystemandtheflow-oneffectsthroughthisqualitypracticethroughouttheirsupplychain.Onceaquality,readableGS1 logistics label isappliedintherightlocationtotherightpallet,productscanbetracedthroughthesupplychain.

To ensure consistent barcode quality,CUB Yatala has a comprehensive servicecontractwithinsigniathatcoverspreventativemaintenanceandbreakdowns.ThismeansthattheirpalletscontinuetogooutthedoormeetingGS1standards.insignia Pty Ltd


http://www.pca-aus.com.au


NEWPRODUCTS

How do you improve reliability and still save money?

Improve reliability with UE electronic pressure and temperature Switches. Available for hazardous locations the One Series provides precise control and features Plugged Port detection.

■ Solid State design with no moving parts■ Field programmable for set point and deadband control■ 2-Wire design is a drop-in replacement for mechanical switches■ IAW®(I am working) self diagnostics■ Pressure ranges to 4500 psi/Temp. ranges to 1000°F

Pryde Measurement Pty LtdPh: 1800 688 211 [email protected] ❘ Sydney ❘ Brisbane ❘ Perth

UE Solid State Pressure Switches

WIRELESS REMOTE NETWORK MODULEThe WNM wireless network module from Moore Industries provides a low-cost wireless communications link

between field sites that are in rugged or impassable terrain, with a single unit transmitting for up to 48 km

and the ability to act as a repeater for a virtually unlimited transmission range, and in both point-to-point

and point-to-multipoint network architectures.

The bidirectional WNM employs spread spectrum frequency hopping technology to avoid interference

problems caused by crowded radio spectra. This technology allows multiple radio networks to use the

same band while in close proximity. Operating at standard operating frequencies of 902 to 928 MHz

(48 km range) or 2.4 to 2.4835 GHz (24 km range), the WNM does not require a regulatory licence and

can typically be installed without performing costly RF site surveys.

When it is set in the Smart Switch Ethernet (SSE) mode, the WNM enhances the speed and reliability of

data packet transmission by determining the most efficient path of broadcast (including direct to

a single radio or to some or all radios in a network) on a packet-by-packet basis.

The WNM can be used with the Moore Industries NCS NET Concentrator System, as well as

other SCADA and distributed I/O systems. WNM models are available for data communications

networks that use ethernet and serial (RS485) communications.

The WNM utilises 128-bit AES encryption, 32-bit CRC error detection and ARQ for robust and

secure communications. The industrial DIN rail-mount metal enclosure also ensures that the WNM

can be used in rugged environments, including ambient temperatures from -40 to 75°C and rela-

tive humidity of 5 to 95%.

Moore Industries Pacific Inc


http://www.harting.com.au


NEWPRODUCTS

Offering ratings from 0.18kW to 15kW, the Altivar 32 has been designed specifically for the control of motors in machines requiring a high level of safety and functionality.

Features:

> Compact design for vertical or side-mounting.

> Integrated safety and programmable logic functions for adaptation to specific application needs.

> Integrated Bluetooth® and communications with all major protocols.

Introducing the Altivar 32

www.schneider-electric.com.au | Call 1300 369 233© 2012 Schneider Electric. All Rights Reserved. CLIPCOM24382

A modular, solution-based variable speed drive, featuring a built-in logic controller and safety functions.

High density installation possibilities

Compact and shallow mounting (90° faceplate)Download the Altivar 32 brochure plus a FREE copy of SoMove

Software and explore the logic and safety possibilities today!

Simply visit www.SEReply.com and enter key code 52493K

Discover more

WEB-BASED OPERATOR PANELSThe Phoenix Contact range of web-based operator panels now comes in

10 and 15″ versions. The larger display area has the advantage that fewer

process diagrams have to be configured to display all operating data. For

operator panels with small displays, information is distributed across various

process diagrams. The navigation between the process diagrams defines

how quickly and intuitively this operation can be performed. By using large

displays, the risks involved in navigation are reduced, as users can see all

of the information at a glance.

The web panels with screen diagonals of 26.42 cm (10.5″) and 38.1 cm

(15.1″) have a colour TFT touch screen. They have a resolution of 800 x 600

or 1024 x 768 pixels and can display 65k colours. Both devices are based

on a RISC ARM9 platform, sporting a 200 MHz processor. These devices are

factory equipped with one ethernet and two USB ports.

These panels are used in equipment and small machines where basic HMI

functionality is required. All web panels use the simple and free Web Visit

development environment to visualise process flows, whereby a compact con-

trol is connected to the web panel as a web server for data processing and

visualisation. Data is displayed using the microbrowser integrated in the panel.

Phoenix Contact Pty Ltd



In Part 1 of this article we looked at standard methods of Layer 2 networkredundancy that involve auto-reconfiguration of the network topology aftera failure. This time we continue and look at redundancy methods that arefully redundant.

As we saw in Part 1 of this article, link aggregation,spanning tree protocols and MRP, along with a hostof proprietary redundancy protocols, provide many op-tions for configuring networks for automatic failover.

Redundancy protocols can also be combined to further enhancenetwork availability.

Othermethodsofachievingredundancy(usuallyusingproprietarymethods) are dual-homing and ring coupling.

Dual-homing and ring couplingOneexample of redundancy techniques that are basedonpropri-etary technology is dual-homing protocols, also known as redun-dant couplingprotocols.Theyusuallyhavea recovery time in the200ms range.Although theymaybe installedas thesole redun-dancymethod, they aremore typically used in tandemwith othermethods. They are used to give redundancy, or to connect ringtopologies, to enable redundant links between rings or betweenother lower level networks and a higher-level network. All datarunsthroughaprimarylinkand,onfailure,abackuplinkisopened.Usually, both the primary and secondary links connect with twoseparate switches in the lower level network so that therewouldbenosinglepointoffailure.Forexample,withredundantringnet-works,oneprocessareamightbeput intooneringwhileanotherprocessareawouldbeconfiguredintoaseparatering,withalltheinformationdirectedtoacentralcontrolstationorhistorianserver(Figure1).Eachringorprocesswouldberedundantlycoupledbackto the main or backbone network so that the flow of informationwould not be interrupted.

Zero recovery time technologiesThe Layer 2 redundancy methods we have examined so far havethree basic weaknesses:1. They provide redundancy at the switch/network level, but not

rightdowntotheenddevice.Ifthelinkbetweentheenddeviceand the switch should fail, then the device will be unable tocommunicate, the effect of which will depend on the deviceand the process.

2. Theyprovideredundancyforlinks,butnotforentireswitches.Ifaswitchfails,alldevicesconnectedtotheswitchbecomecutoff.

3. They have a finite, and often not deterministic, recovery time,whichmaybeaproblemforsomehighperformanceapplications.Anexampleofanapplicationwhereaslowornon-deterministic

recoverytimecanbeanissueisinsubstationautomation.IntelligentElectronicDevices(IEDs)isthenameusedforthetechnologythathascometoreplaceprotectionrelaysandothertechnologyforhighvoltagecircuitcontrol.Today,manyofthesedeviceshaveethernetinterfaces and, in a typical substation environment, communicate

with each other and the higher level SCADA systemvia ethernetusingtheIEC61850protocol.Underthisprotocol,sampledatamaybe collected up to 256 times per 50 Hz cycle (or 12,800 timespersecond)andnetwork latency isasignificantconsideration fornetworkdesign,undernormaloperatingconditions.Thesenetworksare also implemented in an environment where large surges andEMIburstsarecommonplace.Ifitisintendedthatnetworkfailuresbeaccommodatedinthedesign,thentherecoverytimeofstandardredundancy protocols may not be fast enough to ensure no lossof important data.

Inordertoovercomethesethreelimitations,twonewstandard-ised technologies are available which allow for two independentpaths between any two devices, providing complete communica-tion redundancy. They are both specified in IEC 62439-3. The bigadvantage of both these protocols is zero reconfiguration time,guaranteeing the highest communication availability.

Parallel Redundancy ProtocolParallel Redundancy Protocol (PRP) is implemented in the enddevicesandtwoindependentpathsareconfiguredtoexistbetweenthese end devices. The two networks are completely separatedand are assumed to be fail-independent. They can have the sametopologyor be completely different and can also internally imple-ment previously discussed redundancy protocols. The end devicedoesnotneedtobe‘aware’ofanyofthefeaturesofthenetworksthemselves (Figure 2).

AsourcenodewithPRPfunctionalitysimultaneouslysendstwocopies of a frame, one over each of two ports. The two framestravel throughtheir respectiveseparatenetworksuntil they reachadestinationnode,inthefault-freecase,withacertaintimeskew.Thedestinationnodeacceptsthefirstframeofapairanddiscardsthesecond,takingadvantageofasequencenumberineachframethat is incremented for each frame sent.

The result is that, as long as one network is operational, thedestination always receives one frame. This protocol provides azero-time recovery and allows the redundancy to be continuouslychecked to detect failures. The only inefficiency in this design,however,appearstobethattheredundancycontrol information islate in the frame and the message has to be processed in orderto determine if it is a duplicate.

For PRP to work it must be implemented in software in theend nodes - the switches are standard devices and do not needto have any PRP functionality. An end device with PRP func-tionality is a Double Attached Node (DAN), having a connectionto both networks.

A standard device with a single network interface (a SingleAttached Node, or SAN) can only be attached to one network.

Industrialethernet

36WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012

Such a device has no redundant path in the event of networkfailurebetweenitandanotherSAN.AdevicecalledaRedundancyBox(RedBox)canbeused,however,toconnectstandarddevices(or networks of standard devices) to both networks.

In many implementations, only the critical devices need beDANs, while non-critical devices can remain as SANs or beconnected through a RedBox. The RedBox implements the PRPfor all the SANs attached to it as a type of redundancy proxy.

Thissystemworksseamlesslyprovidedbothnetworksdonotexperienceafailureatthesametime.Availabilitycanbeenhancedfurtherbyimplementingstandardredundancyprotocolswithinthetwo networks, independently.

If we overlook the cost disadvantage of duplicated networkhardware, the main cost advantages of PRP are:

•Static redundancy reduces network engineering costs•Thelowerlikelihoodofnetworkoutagesreducesoperational

costs•The use of standard ethernet hardware•Critical and non-critical systems can exist on a single net-

work, rather than having to implement separate networks.

High Availability Seamless RingHighAvailabilitySeamlessRing(HSR)isimplementedinaringtopol-ogywithDANsconnectedtoeachother ina ringwithoutdedicatedethernet switches. Nodes within the ring must be HSR-capableswitchingnodes.

HSRworksbypassingthe framesaroundthering inbothdirec-tionsatonce,resultinginahalvingoftheavailablebandwidth.Unicastframes,whenreceivedbythedestinationnode,areremovedfromtheringandthedatapasseduptotheapplicationonthatnode.Multicastandbroadcastframes,whenreceived,willbeforwardedontheotherring port. The sending node is responsible for removing the framewhen it has traversed all the way around the ring, to avoid framescirculating forever.

General purpose SANs cannot be attached directly to a HSR,exceptvia aHSRRedBox (Figure3).

The advantage of HSR rings is that, like PRP, there is seamlessfailover.Unfortunately,beinga ringtopology, it cannot recover frommultiplefailuresinasinglering.Beingimplementedinhardware,itsapplicationisinhigh-speednetworksthatrequireinstantredundancyforasinglefailure,suchasinsubstationnetworksandmotioncontrol.

Industrialethernet

Figure 1: Dual-homing and ring coupling may be used if these protocols are supported by the switches.

Figure 2: An example of a a redundannt configuration using PRP. The redundancy box acts like a redundancy proxy for the

SANs attached to it.


Therehavealsobeenconcernsraisedinsomequartersthatthefactthatalltrafficmustgothroughalldevices(twice)meansthat,inlargeimplementations,thenetworkspeedmayneedtobemorethan1Gbps.

Theuseofspecialisedhardwareinterfacesallowstheupper-layerapplication and protocol stack to be ‘unaware’ of the underlying re-dundancy topology, but the disadvantage of this is the necessity forthis specialisedhardware.PRP, on theotherhand, doesnot requirespecialised hardware as it still uses standard ethernet switchingtechnology.PRP’soverallperformancehowever isdependentonthestandardnetworks it is implementedover.

But, likePRP,HSRprovidesother cost benefits:•Static redundancy reducesnetworkengineeringcosts

•Thelowerlikelihoodofnetworkoutagesreducesoperationalcosts

•Critical andnon-critical systemscanexistona singlenetwork,rather thanhaving to implement separatenetworks.

HSRalsodefinesadoubleRedBoxknownasa‘QuadBox’thatcanbe used to link HSR rings together. Complex topologies, including‘rings of rings’ can be implemented. HSR rings can also be main-tainedonly forthehigh-speedcriticalpartsofthenetwork (suchasfornetworksof IEDs insubstations)andbeconnectedviaaRedBox

to a standard RSTP or MRP redundant network as a backbone, oreven to a PRP network using two RedBoxes - one for each of thetwoPRPnetworks.Figure4showsanexampleofmixingHSRandPRP in a redundantnetwork.

ConclusionIn today's automation applications, RSTP and MRP are the redun-dancy control protocols typically used, or alternatively a range ofproprietaryprotocols (seebreakoutbox).Most, ifnotall, industrialethernetswitcheshaveRSTPandMRPredundancycontrolprotocolsimplemented and have proved their worth. These protocols covermost requirements, but there have always been applications thatcannottolerateafailureofevenafewmilliseconds.Untilnowtherehas been no effective way to overcome this problem.

But now, with the coming availability of PRP and HSR, it willbe possible to implement zero-changeover, fault-tolerant networkarchitectures. However, both PRP and HSR are very new. WhilePRP is already in use in some applications, HSR is still very newand is dependent on the development of equipment with HSR in-terface hardware.

Industrialethernet

WITH THE COMING AVAILABILITY OF PRP AND

HSR, IT WILL BE POSSIBLE TO IMPLEMENT

ZERO-CHANGEOVER FAULT-TOLERANT

NETWORKS ARCHITECTURES.

Figure 3: A typical HSR configuration. Single attached nodes cannot be connected directly to the ring as in PRP.

Figure 4: An example of mixing HSR and PRP in a redundant network.


COMPACT RTUSemaphore has announced that the

T-Box LT RTU (Remote Terminal Unit)

product line for remote monitoring

and SCADA system applications has

passed operations testing at -40°C.

The T-Box LT is a compact, rug-

ged platform with up to 32 I/O points.

Integral communications include eth-

ernet, RS-232, RS-485 two-wire and

a choice of PSTN modem, GSM/

GPRS modem, GSM 3G mo-

dem, spread spectrum radio or

RS-232 with full modem control.

T-Box employs a decentral-

ised architecture that enables the

complete integration of programmable

automation, alarm management, data logging

and IP telemetry in a single package, Semaphore

claims. Platforms leverage web technologies and push

messaging via e-mail, SMS text and FTP.

The easily configured T-Box products are suitable for

a range of monitoring and control applications in the as-

set management, broadcast/telecom, oil and gas, power,

transportation, water and wastewater industries.

CSE-Semaphore Pty Ltd


now available online!

NEW White Papers

For these and more White Paper downloads, visit www.processonline.com.au/white_papers

MACHINE-MOUNT IP67 POWER SUPPLIESBalluff’s IP67 intelligent

power supplies are de-

signed to mount directly

on machines such as

conveyors, and with Bal-

luff’s Heartbeat technol-

ogy maintenance crews

get feedback on the

real-time and long-term

status of the supply to

enable prediction of

the replacement and

maintenance cycle of

the supply.

They offer greater than 93% efficiency and can provide

power boost of 150% for up to 4 s. Being mechanically

durable to vibration and shock, they are deisgned for a

minimum service life of 15 years.

Balluff-Leuze Pty Ltd


NEWPRODUCTS

Alarm rationalisationAlarm rationalisation is a systematic process to evaluate potential

or existing alarms, qualify which are legitimate, specify their

design and capture rationales which can be used to guide

operator response. This paper describes the SILAlarm solution

and other tips for setting up and sustaining an effective alarm

rationalisation process.

Oxygen measurement on air separation plantsIndustry consumes vast quantities of oxygen and nitrogen

annually, all of which is obtained from the air around us. There are

two main techniques used to separate these two primary gases

from air. These processes are cryogenic separation and pressure

swing adsorption (PSA).

8 steps to validating/mapping a chamberPeriodic mapping of conditions within environmental chambers

is critical for compliance in FDA-regulated applications, where

validation of conditions such as temperature, and sometimes

humidity, is mandated. This application note details the eight

steps users should follow to ensure good manufacturing practice.

Four ways to save energy in your drive automationWith today<0x2019>s soaring energy costs, it is important for

industry to reduce energy consumption wherever possible.

Electric motor-driven equipment accounts for almost 65% of

electricity consumed in the manufacturing sector, meaning

improving the efficiency of motor and drive systems is a major

consideration for cost cutting.

www.processonline.com.au

http://www.idc-online.com


WIRELESS AP/BRIDGE WITH M12 CONNECTORSStrong vibrations, moisture and dust created by industrial machinery can cause data con-

nections to become loose. Where a network device is connected to the control centre via

a wireless link, an unstable wired connection between the device and the wireless access

point impedes the efficiencies gained by wirelessly accessing the equipment.

Created specifically for applications where strong vibrations can cause networking prob-

lems, the AWK-3131-M12 from Moxa provides the secure reliability of M12 connectors and

protect wired connections from the inevitable wear and tear of vibration, moisture and dust.

The AWK-3131 is Moxa’s basic indoor wireless access point/client/bridge that is built to the

802.11n standard, making it backwards compliant with 802.11a/b/g.

The entire device is housed in a sturdy IP30, full-metal casing and features Power over

Ethernet+, redundant power jacks and Turbo Roaming to provide a wireless connection that

can reach data transfers of 300 Mbps and roaming handoffs as quickly as 50 ms, when paired

with other Moxa hardware. MIMO technology icreases data throughput (up to 300 Mbps)

and range. The AWK-3131-M12 also has an operating temperature range of -40 to 75°C.

Madison Technologies


FREE SUBSCRIPTION!What’s New in Process Technology is FREE to qualified industry professionals in Australia & New Zealand.

To continue receiving your free copy you will be asked to register every three years.

Quick registration @ www.ProcessOnline.com.au/subscribe

NEWPRODUCTS

ENCLOSURE COOLINGRittal’s energy-saving ‘Blue e’ enclosure cooling units offer a cooling output ranging from

500 W to 4 kW (depending on the application) and are claimed to achieve energy savings of

as much as 70%.

In terms of size and appearance, the Blue e cooling units are similar to Rittal’s TopTherm

system, but with a 42% higher coefficient of performance (COP) - up from 1.2 to 1.7.

The efficiency of the cooling units is firstly related to the design of the condensers, evapora-

tors, cooling fins, pipe bends and all the other refrigeration components.

Rittal also optimised the fan technology. Electronic commutation (EC) technology is used

in most of the fan motors. In these motors, designed as external rotor motors, the traditional

mechanical pole reversal is replaced by electronic commutation, which functions without wear,

sparks or interference. The motors have a dynamically balanced rotor with multipolar magnets.

The rotor position is recorded by several Hall effect sensors. Motor supply and control is via an

external electronic operating system that has a high efficiency at all speeds. Precision bearings

provide a long service life and low noise generation.

Rittal has improved the control electronics by means of new Eco-Mode controls. If an internal

fan does not need to operate permanently, it is automatically switched off, so cutting energy costs.

Rittal Pty Ltd


PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

ProcessTechnologyRegional Roadshow2012NOW IN ITS

8TH YEAR

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

•Brisbane May 14•Gladstone May 15•Mackay May 16•Townsville May 17

Exhibiting companies include:

To register or for more info visit: www.regionalroadshows.com.au

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Regional Roadshows are designed for you. Don’t miss out ...

NEW TRAINING SESSIONS FOR 2012• TuneaPIDflowloop• TroubleshootasimpleTCP/IPindustrialethernet

network using four simple utilities• Write,installandtestamotorcontrolPLCladder

logic program • BasicsofModbusdatacommunicationsprotocol

installationandtroubleshooting• Arcflashprotectionandprotectivesafetyequipment• Variablespeeddrives—testingandtroubleshooting

Includes FREE: • Access to exhibition• Training sessions - NEW• Lunch and networking drinks• Product demonstrations • Prize draws

Trainingby:Supportedby:

Coming soon ... to a city near you!

NEW vendor training sessions

Queensland


AS I SEE IT

NATIONALOHSHARMONISATION:WILLITARRIVE?

As I travel around the countrysidemeeting many of our customers anddiscussing all of the things that are

currently affecting their businesses, one ofthe things I am often getting asked about isthe current state of the national harmonisa-tion of OHS laws.

Usually the conversation covers the so-called ‘patchwork’ or ‘two-speed’ economywithminingandprofessionalservicesshowingdouble-digit growthwhilemanufacturing andagriculture are lucky to be in positive terri-tory.Addintothattheuncertainlyaroundthetrue impact of a carbon tax on a number ofbusinesses,coupledwithconcernsaboutthechallenges employers see with the flexibilityof the current Fair Work Australia laws, andemployers are finding it challenging to posi-tion their businesses for the future - not tomentiontoattractandretainstaffamidstthelucrative offers from the mining industry.Andthenthere isahighAustraliadollarthatlooks like staying at these levels for at leastthe near future - meaning our home-grownmanufacturingisdoingittoughwhencomparedwith offshore goods.

Little wonder some of our customers arenottoooptimisticaboutthe future.However,one small ray of sunshine was the nationalharmonisation of the OHS laws, especiallyfor largernationalcorporates,as itpromisedreduced administrative costs and greatereconomies of scale. Streamlining the differ-ent state OHS compliance requirements andcreatingnationallyconsistentsafetystandardsshould lead to greater certainty and under-standing of OHS laws and ultimately, bettersafety outcomes for all businesses.

TheharmonisationdeadlinesetbyCOAGin2008 was 1 January 2012, but that deadlinehaswellandtrulypassedwithusseeminglynoclosertothedesiredendstate.WithQueens-land, New South Wales, the two territories(ACT and NT) as well as the Commonwealthpassingthelaws,westillhavefourstatesyetto enact the changes. Both South Australiaand Tasmania are both trying hard and may

introduce the legislation in the near futureas the bills go back and forth within stateparliament. However, Victoria and WesternAustralia have absolutely no urgency, as thelegislation seems to be a fair way off whileboth governments talk about the significanttime needed to further assess its impact ontheir state.

Atatimewhentherearemanycomplexitiesinvolved in creating a safe workplace - thetechnicalities of machine and plant safety,enactingbehaviouralsafetyandculturechangeprograms, stimulating workforce ownershipandsafety leadership,aswellasalltheOHScompliance requirements - the last thingbusinesses need is a confusing legislativeframework. After significant time and effortwe are no closer to harmonisation and wewill be lucky to see anything by 2013.

Unfortunately,itisthesafetyofourpeopleandworkplacesthatwillultimatelysufferandin my travels I have seen a number of com-paniesthatdesperatelyneedallthehelptheycanget - andwith themajority of their timeandeffortfocusedontheotherissuesabove,safetyisnotgettingtheattentionitdeserves.Iurgethegovernmenttoputpoliticsasideandfasttracktheharmonisationsocompaniescangetonwiththejobofrunningtheirbusinessessafer than ever before.

A formally trained chemical engineer, Scott Moffat is the Managing Director of Pilz Australia & New Zealand. He is a senior executive with over 20 years’ experience and extensive knowl-edge in the automa-tion, safety, energy,

mineral processing and petrochemical industries and possesses a unique blend of engineering background and corporate finance coupled with strong business acumen and customer focus.

Printed and bound by Webstar +61 2 9748 0020Print Post Approved PP255003/00198ISSN No. 0819-5447

All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them.Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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Creating outstanding food facilities with our clients since 1918.

www.wiley.com.au Visit us, join the conversation and collaborate with our experts.

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what’s new in process technology apr 2012

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