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?
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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
6WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.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.
8WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/P309
Patented Fluke
technology
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Fluke thermal imagers with IR-Fusion technology may have different on-camera viewing capabilities— all views are available in SmartView® software. ©2012 Fluke Corporation.
Infrared images alone can be difficult to understand, which is why Fluke pioneered IR-Fusion® technology. Fluke IR-Fusion technology is the industry’s only pixel by pixel alignment of digital and infrared images, providing the highest level of clarity and accuracy in the industry. Others have tried to copy, but no one has matched this powerful feature. Turn to Fluke patented IR-Fusion technology to deliver the industry’s best infrared images.
Find out more at www.fluke.com.au
Full infrared: Displays a full screen infrared view for maximum infrared detail.
Picture-in-picture: Maintains a frame of reference by placing an IR “window” within a digital image.
AutoBlend™ mode: Only Fluke has mastered the ability to blend partially-transparent infrared and digital images for easier problem detection.
10WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/M960
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
Contact info and more items like this at wf.net.au/M493
12WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
Allen-Bradley® Micro800™ Family of PLCs Plug-in, customise and expand for seamless performance
The Micro800™ Family of PLCs gives you the best of both worlds with standalone functionality and component capabilities. Together with the Connected Components Workbench™ Software, you get:• Just enough control• One software• Easy to install and maintain • Convenience and connectivity• Part of the Connected Components bundle
The Micro800™ Family of PLCsOutstanding solutions made outstandingly simplewww.rockwellautomation.com.au
Customise
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Micro800_wnipt-half-page_advert_march2012.indd 1 21-Mar-12 3:51:38 PM
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
Contact info and more items like this at wf.net.au/M491
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
Contact info and more items like this at wf.net.au/M920
14WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
HOT PRODUCTSON WWW.PROCESSONLINE.COM.AU THIS MONTH
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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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16WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.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
Contact info and more items like this at wf.net.au/M805
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
Contact info and more items like this at wf.net.au/M803
NEWPRODUCTS
18WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.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
20WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/N103
Figure 2: Power consumption for various control methods.Figure 1: Summary of a VSD’s benefits at various motor operating points.
Motors&drives
22WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/M934
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
Contact info and more items like this at wf.net.au/P164
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
Contact info and more items like this at wf.net.au/N223
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
24WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/M827
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
Contact info and more items like this at wf.net.au/P229
APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 25www.ProcessOnline.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
Contact info and more items like this at wf.net.au/M924
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
Contact info and more items like this at wf.net.au/N114
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
Contact info and more items like this at wf.net.au/P172
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
Contact info and more items like this at wf.net.au/N232
APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 27www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/M708
NEWPRODUCTS
28WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/N189
APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 29www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/N115
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
Contact info and more items like this at wf.net.au/N172
zone sponsor zone partner media partner
Making Air Technology
APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 31www.ProcessOnline.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
Contact info and more items like this at wf.net.au/N001
32WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.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
Contact info and more items like this at wf.net.au/P246
APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 33www.ProcessOnline.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
Contact info and more items like this at wf.net.au/M936
REDUNDANCYININDUSTRIALNETWORKS
PART2Glenn Johnson, Editor
© iS
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APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 35www.ProcessOnline.com.au
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.
APRIL 2012-WHAT'SNEWINPROCESSTECHNOLOGY 37www.ProcessOnline.com.au
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.
38WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/N002
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
Contact info and more items like this at wf.net.au/N162
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
40WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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
Contact info and more items like this at wf.net.au/M995
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
Contact info and more items like this at wf.net.au/N181
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
42WHAT'SNEWINPROCESSTECHNOLOGY-APRIL 2012 www.ProcessOnline.com.au
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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Head Office
Cnr. Fox Valley Road & Kiogle Street,
(Locked Bag 1289)
Wahroonga NSW 2076
AUSTRALIA
ph: +61 2 9487 2700 fx: +61 2 9489 1265
www.westwick-farrow.com.au
ph: +61 3 9381 2952
Editor
Glenn Johnson
Chief Editor
Janette Woodhouse
Publisher
Geoff Hird
Art Director/Production Manager
Julie Wright
Art/Production
Tanya Scarselletti, Colleen Sam, Nettie Teuma
Circulation Manager
Sue Lavery
Copy Control
Mitchie Mullins
Advertising Sales
NSW/QLD - Nicola Fender-Fox
ph: 0414 703 780
VIC/SA/WA - Lachlan Rainey
ph: 0402 157 167
NZ - Jordan King
ph: 0800 44 2529
USA - Huson International Media
East Coast ph: +1 212 268 3344
West Coast ph: +1 408 879 6666
UK - Huson International Media
ph: +44 1932 56 4999
Asia - Lachlan Rainey
ph: +61 (0) 402 157 167
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Sept 2011 total CAB audited circulation (Aust + NZ)7,451 readers (92% personally requested)
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