VOLUME

NO 2 FEBRUARY 2019
35
R26 incl VAT
Official publication of the SAIMC

Bag-in-Box technology
just got faster
Food, beverage & pharmaceutical | Process measurement
Control valves & actuators | Control systems | IT in manufacturing
 VOLUME 35 NO 2 FEBRUARY 2019

OUR COVER 20
REGULARS
VOLUME

NO 2 FEBRUARY 2019
35
R26 incl VAT
Official publication of the SAIMC

Pro Project Machinery, a bespoke

machine building business, is 04 News digest
passionate about using cutting
edge technology to produce 05 News & events
equipment that lasts. See this
month’s cover story on page 20 11 Training
for more on how automation from
Beckhoff helped the company 12 SAIMC news
gain a competitive advantage in
Bag-in-Box technology
just got faster
the Bag-in-Box industry. 16 Nick Denbow
Food, beverage & pharmaceutical | Process measurement
Control valves & actuators | Control systems | IT in manufacturing
18 System integrators

70 Product news

FEATURES
Cover story 20 Bag-in-Box technology just got faster

Food, beverage & pharmaceutical 22 IS3 - Industry Software, Solutions and Support, BLTWorld,
Bosch Holdings, Comtest, Festo, Endress+Hauser,
SICK Automation Southern Africa

Packaging & bottling 29 SICK Automation Southern Africa, Morton Controls

Process measurement 30 SICK Automation Southern Africa, Upat SA, WIKA Instruments,
ASSTech Process Electronics & Instrumentation,
GHM Messtechnik South Africa, Yokogawa South Africa

IT in manufacturing 36 SKF South Africa, RS Components SA, Omron Electronics,

Parker Hannifin SA, RJ Connect, Siemens Digital Factory and
Process Industries and Drives

Enclosures, cabling & accessories 44 Pepperl+Fuchs, Rittal South Africa, RS Components SA

Electrical power & efficiency 46 ElectroMechanica, KSB Pumps and Valves South Africa,
Schneider Electric SA, Accutronics, Siemens Digital Factory and
Process Industries and Drives

Control systems 51 Rockwell Automation, Phoenix Contact South Africa,

Beckhoff Automation, Yokogawa South Africa, Tectra Automation,
ABB South Africa, Omron Electronics, Turck Banner

Condition monitoring 60 Alien Systems & Technologies, Emerson Automation Solutions,

Comtest, Schneider Electric SA, R&C Instrumentation, SKF South Africa

Control valves & actuators 66 Metso South Africa, ifm electronic SA, Valve & Automation,
Macsteel Fluid Control

www.instrumentation.co.za February 2019 1

welcome
???

VOLUME 35 NO 2 FEBRUARY 2019

MANAGING EDITOR

Printing the future

Graeme Bell
NHD Elec Eng (L.C.), MBA
gbell@technews.co.za

EDITOR
Steven Meyer
BSc (Elec Eng), IMM (Unisa)
steven@technews.co.za
In the automotive industry, for example, spare
parts could be printed in the repair shop as DEPUTY EDITOR
Kim Roberts
and when they are required, cutting the need MSc Chem
for inventory and supply chain management. kimroberts@technews.co.za
The raw materials would, of course, have to be CONTRIBUTING EDITORS
held on the premises, so some degree of stock Michael Brown
BSc (Eng) (Rand), CEng MIEE MSAIEE
holding will still exist. Gavin Halse
Among the automation companies, BSc Chem Eng
Oratile Sematle
Metso is one of the first movers in the field. BSc Elec Eng, MBA
For years, Metso Flow Control has been
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exploring the possibilities of the technology for Sales manager
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recently after the company received an urgent Tel: +27 11 543 5806
call from an end user having problems with the Melissa Simons
valves it currently used in a harsh gas treatment melissa@technews.co.za
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Metso used 3D printing technology to create
In a production context, it is considered
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more on how they did it, see the article on
to upset the economics of manufacturing. LETTERS TO THE EDITOR
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2 February 2019 www.instrumentation.co.za

 NEWS DIGEST

Siemens and MineSense to ABB to power Europe’s largest electric

develop real-time ore grade car battery factory
measurement solution
LG Chem has selected ABB to provide a “This substation solution is a good
substation for Europe’s largest electric car example of how ABB brings together
battery factory in Poland. Key equipment domain expertise, best-in-class products
supplies include transformers, surge and system integration capabilities,”
arrestors and gas insulated switchgear that says Patrick Fragman, head of ABB’s Grid
will ensure safe and reliable power supplies. Integration business.
The new plant near Wroclaw will The substation is a key element of the
be capable of supplying up to 250 000 power supply system, linking the grid and
electric cars per annum with batteries. the power supply to the plant. Its proper
It is also the first large-scale lithium-ion operation is crucial for the energy security
battery plant for automotive applications of the plant, especially in case of highly
producing all battery components, from automated facilities, where power supply
electrodes to cells, modules and packs. issues can result in costly downtime.
With ore grades declining, plus added pressures such as
rising energy costs and water restrictions, it is increasingly
difficult for mining companies to fulfil customer demand
by delivering material on time, in the right quantity,
and to the defined quality. To address this, Siemens
and MineSense have formed an exclusive cooperation
on the real-time measurement of ore grade and ore
characteristics for conveyors. By combining each party’s
strengths, the resulting joint solution will, for the first
time, provide real-time measurement of ore grades and
by-products by MineSense’s BeltSense in combination
with a single material and quality management system,
Siemens Simine MAQ. This new and comprehensive
approach will enable customers to significantly increase
efficiency via a single view of quality across the whole
conveying process.

Emerson selected as Industrial IoT company of the year

Emerson has been named the ‘Industrial IoT
Company of the Year’ by IoT Breakthrough
for the second year in a row. The honour
recognises Emerson’s innovation and
leadership in driving IIoT technologies and
strategies for customers in manufacturing
industries such as oil and gas, power, chemical,
life sciences and others.
The IoT Breakthrough Awards, which
received more than 3500 nominations in
2018, recognise innovators, leaders and
visionaries from around the globe in a
range of IoT categories, including industrial,
smart city technology, connected home
and others. With IIoT capabilities, industrial
companies have more potential than
ever to collect real-time data. However,
turning that data into actionable information
and game-changing operational performance
can be a complex process. To help
customers implement IIoT technologies
seamlessly, Emerson pioneered its Plantweb
digital ecosystem, a scalable portfolio of
technologies, software and services that
enables performance improvement in
production, reliability, safety and energy
management.

4 February 2019 www.instrumentation.co.za


New efforts bring hope for Industry 4.0-ready
SA workforce
Industry 4.0 – smart new automation tools
and technologies – are rapidly changing the
face of manufacturing and industry around
the world. Without a concerted effort to
change industry processes and infrastructure,
and upskill the workforce, South Africa risks
falling behind the world in its efforts to
become a player in the global manufacturing
market. However, new industry initiatives are
emerging to address the skills shortfall and
help propel South Africa into a smarter era of
manufacturing.
Speaking ahead of Africa Automation
Fair 2019, automation industry stakeholders
said aligning with the global Industry 4.0
revolution would demand a great deal of
change and progress in South Africa. A key
priority had to be skills, they say.
Dave Wibberley, managing director at
Adroit Technologies, notes that Industry 4.0
in itself is not a ‘silver bullet’ that will change
manufacturing. “Industry 4.0 refers to a set
of tools and services. To be effective, these
tools and services depend on the necessary
resources and knowledge being in place in
processes. You need to achieve world-class
manufacturing and tooling first,” he says.
Frikkie Streicher, business development
manager at process instrumentation
manufacturer Vega, says a greater effort
is needed to develop the automation
engineering skills pipeline, to allow South
African industry to prepare for Industry
4.0: “Automation engineering is not yet
recognised as a separate field in South Africa.
We need to step up our focus on automation
engineering if South Africa is to achieve its
ambitions of becoming a manufacturing
giant in Africa.”
Annemarie van Coller, president of the
Society for Automation, Instrumentation,
Measurement and Control (SAIMC), says
that while automation presents massive
economic growth opportunities, it does
threaten the current environment’s workforce
structure: “If you look at the current ‘triangle
of training’, we have a small number of
engineers at the apex, and a large number of
artisans at the bottom. We need to invert this
triangle and produce a far greater number of
engineers capable of supporting automation
in future.”
Efforts are now underway to fast-track
this process, developing new curricula for
automation engineers and introducing new
learning models to upskill employees.
SAIMC and other industry stakeholders
are moving to introduce a skills development
model for the automation sector, based
on the successful model introduced in the
tooling sector. Driven by Johan Maartens,
SAIMC director & COO, the initiative will see
the launch of an education and training
system for Automation personnel modelled
on the National Tooling Initiative Programme
(NTIP) for the tool and die industry. The
launch of the new programme includes the
renaming and rebranding of the tooling
programme as the National Technologies
Implementation Platform (NTIP) under
the oversight of the Intsimbi Board. The
programme is intended to serve as a
fully-fledged Fourth Industrial Revolution
programme, including training in robotics,
mechatronics and industrial maintenance,
and involving over 500 companies.
Launching the new Intsimbi Future
Production Technologies Initiative (IFPTI)
at NTIP’s Centre of Excellence in Cape Town
earlier this year, Trade and Industry Minister
Rob Davies said the government was
committed to building capacity in response
to the impact and opportunities that Industry
4.0 will bring about.
While funding models and curriculum
development are still under discussion,
van Coller is optimistic that the new initiative
will drive the change the sector needs.
“We’re very excited about this, and its
potential. It will bring new opportunities for
upskilling – gone are the days of being too
old or living too far from a university. This
model allows for free, flexible, home-based
learning using online tools, along with some
facilitator-led learning. Stakeholders are
also looking at the necessary infrastructures
for participants in rural areas with limited
Internet access. It presents the hope that we
can develop our own advanced automation
skills pipeline and stop relying on imported
skills,” she says.
The Connected Industries Conference
at Africa Automation Fair 2019 will focus on
the challenges, opportunities and economic
impact of the Fourth Industrial Revolution
(Industry 4.0 / IIoT) on South and sub-
Saharan Africa.
For more information contact Jayne Harley,
Reed Exhibitions, +27 11 549 8300,
jayne.harley@reedexpoafrica.co.za,
www.africaautomationfair.com
NEWS & EVENTS
Klaus Endress turns 70
Klaus Endress.
Klaus Endress, current President of the Supervisory
Board of the Endress+Hauser Group, who also
served for many years as CEO, celebrated his 70th
birthday on 9 December 2018. He was born in 1948,
the second of eight children of company founder Dr
Georg H Endress and his wife Alice. After completing
his degree in industrial engineering and getting his
professional career off to a start in the US, he joined
his father’s company in 1980. He then took over the
reins in 1995. As CEO, Klaus Endress influenced the
Group’s growth and development for nearly two
decades. He handed over the operational business
to Matthias Altendorf in 2014 and moved to the
Supervisory Board.
Klaus Endress dedicated much of his energy
and attention to fostering the corporate culture, in
which responsibility and loyalty are core elements.
He also invested significant amounts of time in
creating the Family Charter. This document governs
the relationship between the shareholder family and
the company, guides the younger generation into
the business and strengthens the bonds between
the 70 plus members of the family. He is politically
active as a member of the community council in
Reinach, Switzerland, where he resides. In his leisure
time, the passionate horseman and mountain biker
is regularly drawn to the outdoors and nature. Apart
from that, he enjoys spending time with his wife and
two grown children.
For more information contact Endress+Hauser,
+27 11 262 8000, info@za.endress.com,
www.za.endress.com
www.instrumentation.co.za February 2019 5
 NEWS & EVENTS
Adrian Buddingh joins Rittal
South Africa as managing
director
Adrian Buddingh.
Effective as of 1 January, Rittal South Africa is pleased
to welcome Adrian Buddingh as the subsidiary’s new
managing director. Buddingh’s engineering expertise,
knowledge of the industry and passion for people looks
to elevate the brand to new levels and will once again
highlight Rittal’s commitment to the local market. As
a leading systems specialist in South Africa, Rittal is
focused on delivering customer satisfaction and service
underpinned by superior products. Internationally, the
Friedhelm Loh Group has been honoured as one of
Germany’s top employers and the company works
to maintain its desirable employer status on
local shores too.
Buddingh graduated in mechanical engineering and
has a National Higher Diploma in Management Practice
at the University of Johannesburg, as well as a Diploma in
Industrial Marketing at the University of Cape Town.
In an official welcoming of Buddingh, Rittal business
development director Middle East Africa, Ute Remdisch,
acknowledged Buddingh’s culture fit: “We are pleased
to welcome Adrian to the fold. Our team is tight knit
and passionate about our brand. We are confident
that Adrian’s technical knowledge and strong sense
of leadership will deliver great value, support and
innovation to our customers and other stakeholders.”
Buddingh concludes: “It is a great honour for me to
join Rittal. The company services industries which I have
vast experience in and I look forward to working together
with a stellar team to deliver on promises and exceed
expectations.”
For more information contact Rittal South Africa,
+27 11 609 8294, info@rittal.co.za, www.rittal.co.za
6 February 2019 www.instrumentation.co.za
IoT.nxt delivers results at schools in the USA
Energy cost savings are already being
realised at several schools in Florida,
USA, that chose IoT.nxt’s solution to
deliver energy optimisation and reduce
consumption. Since installation started
in September, some schools where the
technology is fully activated and running
have reported savings of up to 15%.
“The roll-out is progressing well and
we expect to have 50 schools running the
IoT solution by the end of the year,” says
Jason Bradlee, COO of IoT.nxt Americas.
“We are very encouraged by the results
already achieved and on the back of that
have been approached by four more
states to introduce similar projects.”
“Many building management
operations use pre-set systems to
switch energy facilities on and off at
particular, fixed times in order to reduce
consumption,” explains IoT.nxt CEO,
Nico Steyn. “IoT strategie allows building
managers to effect optimal usage in
a building. The IoT technology makes
it possible to take various factors, for
instance occupancy and ambient external
temperature, into account to intelligently
adjust energy used to change the
IS³ extends its portfolio
IS³ - Industry Software, Solutions and Support
recently signed an additional contract with
AVEVA, which now extends its portfolio to
include the company’s Engineering Software.
AVEVA’s Engineering Software, tools and
solutions improves engineering efficiencies
for any industrial process. The portfolio
offers integrated Process Engineering and
Simulation, Engineering Design, Project
Execution Solutions and Operator Training
modules. These will enable customers to
reduce capital costs and overall risks, have
an efficient and reliable engineering design
software, improve operations and project
management, and rise above the challenges
temperature in a building or to purify the
air. This way consumption is optimised,
which delivers significant cost savings.”
Bradlee expects strong growth for IoT.
nxt in the USA as the company’s offering is
unlike the majority of IoT solution providers
currently rolling out projects. “IoT.nxt has
real distinction around IoT technology,” he
explains. “There are many point-to-point
IoT offerings, but no other company can
leverage existing infrastructure, which
means no new capital investment is
required. This is a significant differentiator.”
According to Bradlee the company will
use a partnership strategy to drive its growth
in the Americas, since it cannot employ the
number of people it will need in time to
meet the demand of projects currently in
development. Team members from South
Africa are currently in the US to support the
schools roll-out process, and in addition to
Bradlee, are supported by a US based project
manager in Tampa.
For more information contact Daleen
van Wyk, IoT.nxt, +27 83 302 0827,
daleen.vanwyk@iotnxt.com,
www.iotnxt.com
faced by today’s workforce to drive safety and
profitability.
IS³ is currently the only distributor in
the world which offers the complete AVEVA
software portfolio to its customers, which
includes: Asset Performance Management,
Monitoring and Control, Engineering
Software, Planning and Scheduling, and
Operate and Optimise Solutions.
For more information contact Clarise
Rautenbach, IS³ - Industry Software,
Solutions and Support, +27 11 607 8473,
clarise.rautenbach@is3.co.za,
www.is3.co.za

Trialling of dry sorter coal-beneficiation solution
targeted for 2019
Sydney Parkhouse.
Mounting stress on South Africa’s water
resources, combined with growing
concerns about the environmental
impact of mining operations, make Aury
Africa’s dry sorting technology ideal
for environmentally-conscious mining
houses. The company aims to bring its
first dry separator to South Africa for trial
at a coal mine in 2019, reveals business
development manager, George Sturgeon.
The Telligent Dry Separator (TDS)
technology was developed in 2015 and
launched locally at the South African Coal
Processing Society’s biennial conference
in 2017. At that time, three operating
mines in China were using the equipment.
The technology processes raw coal, with
an upper throughput of around 400 tph.
Aury Africa managing director Sydney
Parkhouse explains that coal is conveyed on
an enclosed system that incorporates dual
X-ray technology and is simple to operate. It
can therefore be retrofitted to existing coal-
processing plants in various configurations.
The TDS does not use any water during
operation, which makes it a fundamentally
invaluable technology for ‘greening’ the
coal-mining industry. “There is increasing
focus from mines to be environment-
friendly, with significant pressure on the
coal industry to go ‘green’. This technology
is a push in that direction,” adds Parkhouse.
Currently, 46 TDS systems are either
operational, in commissioning, or contracts
being signed. Aury Africa is considering
different applications for the technology in
the complete mineral beneficiation chain.
For example, a four tonne sample from a
manganese mine in the Northern Cape was
sent to Tianjin in China in July for separation
trials using the TDS.
“Aury Africa invites mining partners
across the commodity spectrum to see
how the TDS can improve yield and
quality at their mines and ultimately
reduce operating and maintenance costs,”
concludes Parkhouse. “The company is
open to procure units for clients in South
Africa to trial at their mines, and to show
them the benefits of the TDS system.”
For more information contact Sydney
Parkhouse, Aury Africa, +27 11 026 6642,
syd@auryafrica.co.za, www.auryafrica.co.za
NEWS & EVENTS
Book early for this year’s X-Change
User Group Conference
The largest industrial software event in Africa, X-Change
2019, is almost upon us. This year X-Change will take
place at the Sun City Resort from the 17-20 March.
X-Change has been a success for a quarter of a century
because it has always delivered three consistent values:
• Business and networking opportunities.
• The key to improved operational benefits.
• Learning the new way of work through Edge to Enterprise.
At X-Change this year, IS³ will be addressing the
addition of AVEVA software to its portfolio.
X-Change also has a jam-packed two-day agenda
focusing on industry sessions specific to mining, minerals
and metals, hybrid, oil and gas and general manufacturing,
including customer success stories, products and solutions.
These sessions and workshops are designed to demon-
strate how Edge to Enterprise transforms business processes
and the entire value chain to align with business goals.
X-Change is an opportunity to learn, share
experiences and network at Africa’s longest running
industrial software event.
Please follow the link to register – www.x-change.co.za
and https://tinyurl.com/y9ur8dph to preview the keynote
speaker.
For more information contact Clarise Rautenbach,
IS3 – Industry Software, Solutions & Support,
+27 11 607 8473, clarise.rautenbach@is3.co.za,
www.is3.co.za
www.instrumentation.co.za February 2019 7
 NEWS & EVENTS
Seapro appointed authorised
distributor of Cla-Val for SADC
Cla-Val recently appointed Seapro South Africa as its sole
agent for the SADC region and also awarded Seapro the
right to produce components and assemble valves in
South Africa, having appointed a local foundry to cast
products to Cla-Val’s high standards and specifications.
Products will be manufactured under licence and will
carry both Cla-Val and Seapro SA branding.
Control valves can save water
South Africa is a water-scarce country and safeguarding the
commodity is therefore essential. “Reducing consumption
is the right thing to do, but water authorities could also
implement other options that could have immediate results,
without relying on the actions of individual households,
industry and business,” says Seapro SA managing director,
Pat Stander. “Pressure management is a key parameter
that allows water distribution systems to operate at peak
while reducing water loss. Using existing system control
valves along with technology that is economical and easily
accessible can do much to protect water resources.”
Local presence, international excellence
Cla-Val has been active in South Africa for more than 40 years,
with many city councils, municipalities, water boards and
power-generating plants in the region using its control valves.
Using aggressive research and development, and
implementing lessons from 80 years of demanding
real-world use, the company has created technologically
advanced electronic and hydraulic control systems, able
to meet the challenges of increasingly complex and
diverse applications. In addition, the electronic products
can be used to communicate systems performance data
using a variety of IT platforms, including the Internet,
scada, GSM/cell phone and satellite.
With DTI compliance now in place, Seapro SA with the
backing of Cla-Val Switzerland has both the products and
technical expertise to assist city councils, municipalities,
and water and irrigation boards with their control valve
requirements, as well as water loss and water demand
management programmes.
For more information contact Pat Stander, Seapro
South Africa, +27 11 397 1126, pat@seaprosa.co.za,
www.seaprosa.co.za
8 February 2019 www.instrumentation.co.za
Fluid Systems Africa official distributor in
Africa for Advanced Pressure Technology
Fluid Systems Africa has been appointed
official distributor in Africa for AP Tech
as its official distributor in Africa and
is looking forward to supporting its
customers in resolving their fluid system
challenges.
AP Tech, also known as Advanced
Pressure Technology, is a manufacturer
of gas handling components – primarily
pressure regulators and valves. AP Tech’s
forte is products to deliver specialty
gases for high purity through ultra-high
purity applications. Starting from the
RS Components introduces robot-based learning
RS Components has announced the
availability of a new product, Sphero’s
SPRK+, which is designed to provide
students with hands-on computer
programming education. Sphero
embraces the understanding that play is a
powerful teacher and its SPRK+ provides
engaging activities and lesson plans for
STEAM (science, technology, engineering,
art, and mathematics) learning.
The new product supports RS’
longstanding programme to support
the learning and development of the
engineers of tomorrow, both at school
and at higher academic levels. Designed
to inspire creativity and invention, the
SPRK+ robot delivers a complete hands-on
experience for young people to learn
about programming and robotics and
share their creations with a community of
other Sphero users.
The SPRK+ robot is designed for use
with the Sphero Edu app. The platform
source vessel to point of use and into the
process tool or equipment itself, AP Tech
products are known to deliver gases with
uncompromising quality, performance
and reliability. The company sets the
ultimate standard for service and support,
traits that are now synonymous with the
brand – AP Tech.
For more information contact, Stuart
Harvey, Fluid Systems, Africa, +27 87 551
1677, stuart@fluidsystemsafrica.co.za,
www.fluidsystemsafrica.co.za
provides learning activities, lesson plans
and games. Combined together, children
can learn to code through simple drawing,
blocks-based coding and JavaScript.
Each SPRK+ robot has a highly durable
scratch-resistant UV-coated polycarbonate
shell and provides an attractive built-in
LED-supplied glow. It is controllable by
users via Bluetooth Smart and can be
charged up via inductive charging, which
provides more than one hour of use on a
full battery. New product features can be
introduced via app and firmware updates.
In addition to the availability of the
individual Sphero SPRK+ robot, a special
education pack that includes a set of
12 robots is available for purchase by
educational institutions.
For more information contact RS
Components SA, +27 11 691 9300,
sales.za@rs-components.com,
www.rsonline.co.za
 NEWS & EVENTS
VEGA Controls
SA appoints new
managing director
VEGA Controls SA has announced the
appointment of Fredrick Streicher as the
company’s new managing director, effective
from 1 January. He has been with the company
for the last thirteen years where he was
employed as a field sales engineer and in 2015
promoted to sales manager. No stranger to the
process automation industry, Streicher says as
follows about his approach to the future: “Our
values and principles are excellence in service
through innovation by people who care. Their
talents and efforts have already helped us
achieve excellence in many areas.”
For more information contact Chantal
Groom, VEGA Controls SA, +27 11 795 3249,
chantal.groom@vega.com, www.vega.com
Appointment
GHM Messtechnik has appointed Flippie Botha
as sales engineer.
10 February 2019 www.instrumentation.co.za
International analytica trade fair to arrive in SA in 2019
International exhibition organiser, Messe
Muenchen South Africa, has acquired Lab
Africa, South Africa’s only laboratory and
analysis trade fair, set to deliver a bigger
exhibition with broader reach in 2019.
The new Lab Africa fair, to be staged
at Gallagher Convention Centre in Midrand
from 9-11 July, will bring to Africa the
best of international analytica-related
trade fairs, as well as co-locations with
food and drink technology Africa (FDT Africa),
the premier trade fair for processing,
filling, packaging and logistics, as well as
IFAT Africa – the premier environmental
technology show for water, sewage, refuse and
recycling.
This arrangement will allow decision-
makers across the food and drink, chemical,
pharmaceutical, medical, agriculture, water
and waste, as well as academics, value
chains and many other fields to explore the
latest laboratory equipment and analysis
solutions. The exciting new concept creates
a joint platform for up to 6000 visitors to
RS Components bolsters education with tools to inspire
young engineers
RS Components has introduced new ranges
from Seeed Studio, Arduino and Bare
Conductive that target academic institutions,
including educators and students of electronics,
as well as inspiring electronics design engineers
with new projects and prototypes.
The first launch is the Seeed Studio
hardware innovation platform, which
specialises in open-source electronic modules
and embedded devices for designers and
makers. The platform includes the Grove series
of modules and starter kits, including the
GrovePi+ Starter Kit for Raspberry Pi, and the
BeagleBone Green.
The second is the Arduino Engineering
Kit, which targets a range of users including
students learning about engineering at a
university or at a secondary school, and
engineering professors that want practical
resources to demonstrate engineering
concepts to their students.
In conjunction with the Arduino online
platform, the kit includes three projects to help
students learn about fundamental engineering
concepts, key aspects of mechatronics,
and Matlab and Simulink programming for
system modelling and embedded algorithm
development. Buildable projects in the kit
explore trends and innovations in the field
of laboratory and analysis, environmental
technology, and the food and beverage
industries.
About analytica Lab Africa
Lab Africa will feature local and international
market leaders in the laboratory, analysis and
biotechnology industries. It is a part of the
worldwide network of exhibitions, featuring
international innovations and trends precisely
tailored to the local market. Presented by
leading international exhibition organiser
Messe Muenchen South Africa, it will bring to
Africa the full spectrum of laboratory, analysis,
biotechnology and diagnostics, food and
beverage production, and water, sewage,
refuse and recycling technology.
For more information contact
Leigh Angelo, Messe Muenchen
South Africa, +27 11 869 9153,
leigh@tradeprojects.co.za,
www.analytica-africa.com
include a self-balancing motorcycle, a mobile
rover, and a whiteboard drawing robot.
The kit includes an easy-to-use Arduino
MKR1000 board, several customised parts,
and a complete set of components required to
assemble all three projects.
Lastly, RS has also made available three
educational kits that use conductive paint
from Bare Conductive: the ‘Printed Sensors’ set
comprises three A5 printed sensors and enables
users to integrate touch sensors into any project;
the Lamp Kit enables the building of touch,
dimmer and proximity lamps; and the Pro Kit
includes all the required tools and resources to
prototype Electric Paint and Touch Board projects.
Lance Hemmings, senior category
manager semiconductors and optoelectronics
commented: “The launch of these educational
products and technologies demonstrates our
continuing commitment to educators and
students and our belief that it is critical to
support young engineering talent, whether
they are at school or university.”
For more information contact
RS Components SA, +27 11 691 9300,
sales.za@rs-components.com,
www.rsonline.co.za

• Automation Engineers
TwinCAT 3 and TwinCAT 2
Durban 5-7 Mar 2019
Johannesburg 12-14 Mar 2019
Port Elizabeth 26-28 Mar 2019
For more information contact Andrew Reinhold,
Beckhoff Automation, +27 11 795 2898,
training@beckhoff.co.za,
http://www.beckhoff.co.za/za/support/trainin
• Instrument Technicians
and Engineers
TC1001 – Process Measurement and
Instrument Configuration 1
Sandton 4-8 Mar 2019
TC1002 – Process Measurement and
Instrument Configuration 2
Sandton 11-14 Mar 2019
TC1003 – Process Measurement and
Instrument Configuration 1 & 2
Sandton 4-14 Mar 2019
For more information contact Nico Marneweck,
Endress+Hauser, +27 11 262 8087,
nico.marneweck@za.endress.com,
www.za.endress.com
• Mechatronic Engineers
• Maintenance and Repair Staff
HY152 – Mobile Hydraulics
Johannesburg 26 Feb – 1 Mar 2019
PN111 – Modern Industrial Pneumatics
Cape Town 5-8 Mar 2019
PN100 – Introduction to Modern Industrial
Pneumatics
Cape Town 11-12 Mar 2019
For more information contact Sammy Kanye,
Festo, +27 11 971 5586,
DidacticTaC.za@festo.com,
https://www.festo-didactic.com/za-
en/training-and-consulting/courses/
• Radiation Protection Officers
Radiation Protection Officers –
Training Course on The Use of
Radioactive Isotopes for Industrial
Measurement
Johannesburg 26-27 Feb 2019
For more information contact
Michelle Ramphal, Mecosa,
+27 11 257 6100,
michelle@mecosa.co.za,
www.mecosa.co.za
• Automation Engineers
SLP1 – Surge and Lightning Protection
Johannesburg 14 Feb 2019
IWN1 – Industrial Wireless & Networking
Johannesburg 28 Mar 2019
EPFS1 – Explosion Protection &
Functional Safety
Johannesburg 11 Apr 2019
For more information contact
Sheree Britz, Phoenix Contact,
+27 11 801 8200,
sbritz@phoenixcontact.co.za,
www.phoenixcontact.com
• Mechatronic Engineers
PNEU0021 – Basic Pneumatics
Durban 27 Feb – 1 Mar 2019
PNEU0021 – Basic Pneumatics
Cape Town 27-29 Mar 2019
For more information contact
Riaan van Eck,
SMC Corporation South Africa,
+27 11 100 5866, rvaneck@smcza.co.za,
www.smcza.co.za
TRAINING
• Automation Engineers
CPS – Centrifugal Pump Selection
Johannesburg 14-15 Mar 2019
PLCI – PLC Introduction
Johannesburg 27-29 Mar 2019
For more information contact Eric Carter,
turboTRAIN, +27 83 300 3321,
eric@turbotrain.co.za, http://turbotrain.
co.za/instrument-workshops
• Automation Engineers
VPMT – Centum VP Maintenance
Randburg 4-6 Mar 2019
PCIW – ISA100.11a Wireless
Randburg 19-20 Mar 2019
PRDP – Profibus
Randburg 26-28 Mar 2019
For more information contact
Angelique Human, Yokogawa South Africa,
+27 11 831 6300, training@za.yokogawa.com,
www.yokogawa.com/za
• Automation Engineers
Measurement Solutions – Processing with
Level, Pressure and Nucleonic
Roodepoort 12-14 Mar 2019
For more information contact
Claudia Olver, VEGA Controls SA,
+27 73 172 1437,
claudia.olver@vega.com,
www.vega.com
www.instrumentation.co.za February 2019 11
 SAIMC NEWS

From the President’s desk

National Patron Members
Congratulations to all the elected branch
committee members following the AGMs in
January!
Thank you for taking the time to commit
in helping within the SAIMC in this way. Your
work will ensure that our members get the
opportunity to network and also learn about
the relevant technology within our industry.
Enjoy this year with your committee. Please
bring your ideas to ensure that the SAIMC is
continuously improving. We are excited to
see what the teams will deliver.
Using data more proactively and
consciously
Most companies are shifting their focus on
data analytics. And one has to critically ask if
the opportunities to use the data available are
really being used and planned for in company
strategies. Projections show that with the
increase in data availability with the use of
5G technology, that less that 25% of the data
available will be used within industry. IoT will
truly change the landscape as we perceive it
currently.
Using as an example the ‘Future X’
architecture example. Architects will
build networks towards used case led
deployment. Employing strategies that
include:
• Business applications: Including
workforce efficiency and asset
optimisation.
• Digital value platform: Including
digital operations and industrial
automation.
• Multi cloud connectivity.
• High performance networking.
• Dynamic security: Ensuring your data is
protected.
We are living in exciting times for
automation. Companies have the opportunity
to redefine and enhance themselves by using
data. It is exciting to be part of this era of
evolution.
Until I write to you again
Annemarie

Branches

Johannesburg: Ann de Beer at ann.debeer@wika.com; Mobile: +27 82 365 7856

Cape Town: Wade Shuttleworth at wade@Calibreza.com; Mobile: +27 81 899 9234,

Durban: Hennie Prinsloo at hennie@specas.co.za; Mobile: +27 82 324 5379

Richards Bay: Mervyn Govender at mervyn.govender@rbm.co.za; Mobile: +27 83 299 2260

Secunda: Johan Maritz at johanmaritz260@gmail.com; Mobile: +27 82 856 3865

Tshwane : Petrus Klopper at petrus.klopper@ai2sa.co.za; Mobile: +27 82 559 7437

Vaal: Juaandré Heyneke at juaandre.heyneke@wika.com; Mobile: +27 82 664 7884

Zambia: Enock Shikabeta at enockshikabeta@yahoo.com, Tel: +26 97 759 1936

Rustenburg: Mervyn Bartle at bartle.mervyn@gmail.com; Mobile: +27 82 920 5266

Council: Ina at admin@saimc.co.za, Mobile: +27 82 440 8957, Tel: 08610 72462 (08610 SAIMC)

12 February 2019 www.instrumentation.co.za

 SAIMC NEWS

Cape Town branch Tshwane

The branch hosted its end of year function
on 30 November 2018, the first since the
new committee took over in October
2017.
The evening began with a
technical presentation hosted by
Quintin McCutcheon from Schneider
Electric. Quintin presented on Artificial
Intelligence and as per usual was an
extremely animated and engaging
presenter. Members and guests
thoroughly enjoyed the presentation and
were excited about the future prospects
associated with AI in the industrial
sector. The presentation included a brief
history of AI and related the increase in
development to data volumes, advanced
algorithms, improvements in computing
power, networking and data storage. It
also included a number of entertaining
AI videos.
Next stop was a brewery tour at the
main Devils Peak Brewery in Goodwood
where tour guide JC Steyn, the head
brewer at Devil Peak, walked us through
the entire facility and related the story
of how the brewery originated, and
how it has developed into one of the
most high-tech craft breweries in South
Africa.
Initially it was started on small
premises in Somerset West by Greg Crum
with a maximum capacity of 6000 litres a
month. As demand grew it relocated to
Salt River in Cape Town, and later to its
current facility Gunner Cir in Goodwood,
which allowed the brewery to expand
the range of beers produced and also
to experiment with specialist and limited-
edition varieties.
Members and guests then retired to
the Tap Room, for snacks and welcome
beverages. All in all, it was a great evening
of knowledge and networking.
The branch thanks Quintin
McCutcheon for his informative
presentation and JC Steyn for the Devils
Peak Brewery tour.
branch
The highlight of 2018 was the annual dinner enjoyed
by branch members and the committee at Cheers in
Irene. We were also very fortunate to have Ina and Johan
Maartens join us towards the end of the evening.
The other noteworthy item was the meeting
during December of committee members from the
Johannesburg and Tshwane branches to strategise
around collaboration opportunities. The meeting was
also attended by vice president Pregs Naidoo. Topics
discussed included score card and focus areas for
2019, new committee activities i.e. societal focus on
community, schools, etc., golf day, site visits, training
days and finally a relationship committee (i.e. to get more
members, end users, patrons, etc.). It is important to note
that the two branches will be working closely across
Gauteng to leverage synergies that we feel will add
additional value to our patrons and members. A call for
support from the members to assist will be raised as part
of the upcoming AGM.
In conclusion, the branch wishes all members a
prosperous 2019.

Johannesburg branch
Happy New Year from the
Johannesburg team
The year has kicked off with barely a bump
in the road and being back at work you
realise that nothing much has changed.
Except our attitudes, starting the year off
motivated and excited about whatever
2019 will bring – we wish everyone a
happy and prosperous New Year.
Reflecting on 2018 makes me realise
that we achieved much more than
expected. The branch held a total of eight
technology evenings on various exciting
topics. Our training day held in November
was very well attended and I feel confident
that we all learnt something new. From
the social perspective, our golf day held at
Jackal Creek was a resounding success and
the year-end function at Parkers Comedy
Club ended 2018 with much laughter.
2019 promises to be a year full off
technology evenings, golf events, ladies
tea and more. I look forward to seeing you
all there.

Ann de Beer.

www.instrumentation.co.za February 2019 13

 SAIMC NEWS

Durban branch
Technology evening
The final technology evening of 2018 was held
on the 5 December at the Durban Country
Club. Ajanth Sewpersad, sales engineer for
SICK Automation, gave an informative and
well-balanced talk on emission monitoring,
the legal requirements and techniques. The
audience was introduced to The National
Environmental Management: Air Quality Act
(2004), and the measures required therein for
compliance were highlighted. Other related
standards that were listed included several
British (EN) standards.
Following from there, Ajanth covered
Quality Assurance of an Automated Measuring
System (AMS) according to EN14181, and
explained terms and definitions associated
with emission monitoring before covering
some basic principles of alternative continuous Hennie Prinsloo (right) thanks Ajanth Sewpersad after the presentation.
measurement techniques. The verification
method using isokinetic sampling by an monitoring as applied in industry to determine monitoring in a coal fired power station as
independent authority was then discussed, the efficiency of filtration/precipitation widely applied by Eskom. Some equipment
which led to some questions and subsequent systems, achieved by measuring the dust was also on display so that members could
debate later in the meeting. burden before and after it has been extracted view typical monitoring assemblies and ask
The relative advantages and disadvantages from a flue gas. The reasons for different more detailed questions after the presentation
of in-situ gas analysis and extractive analysis applications requiring either light transmission concluded. The meeting then adjourned to
were explained, with the alternatives of cold or light scattering were also explained. enjoy networking over a meal and drinks to
dry and hot wet extractive systems being Ajanth concluded with an overview of the usual high standard of the Durban Country
discussed. Examples were provided of dust typical applications of continuous emission Club.

Annual year-end-function
2018 was a busy year for the branch, which
finished in style at the year-end function,
ably MC’d by Busani Sindibi at the Mount
Edgecombe Country Club.
A balmy November evening (translate to
hot and steamy for the out-of-towners) began
with pre-dinner drinks and photographs
before the 240 guests were invited into the
main hall for the brief formalities. Celebrating
the Platinum Award achievement, chairman
Hennie Prinsloo thanked the committee for
their hard work and commitment. President,
Annemarie van Coller, then applauded the
branch as being the first to achieve this status
and praised the trail-blazing approach as it sets
the bar high for all branches.
At the behest of the committee, Annemarie
thanked Hennie for being such an inspiring
and tireless leader, while everybody agreed all
kudos to him for his contribution as chairman.
With the formalities over, the fun began
with local comedian Jem Atkins breaking the
ice and setting the scene for a relaxed and
convivial evening. It was refreshing to listen to
a comic who did not rely on bad language and
cheap-thrill effects, but who was intelligent
and clever-funny.

Busani Sindibi, MC Hennie Prinsloo, Chairman Annemarie van Coller, President

14 February 2019 www.instrumentation.co.za

 SAIMC NEWS

During the delicious buffet dinner

guests were intrigued and bemused by
the chef who wanted to say thank you and
farewell as he was leaving the country. The
emotional cook somewhat overstepped
the mark with his confession of aspiring
to be a famous singer promptly followed
by a rendition of his favourite song – not
very well delivered! He was sent back to
the kitchen to ‘stuff the tarts’, but it wasn’t
long before he (and the food and beverage
manager) found their voices and came back Arias Anonymous Jem Atkins
to wow the audience with famous arias
sung beautifully.
This was a hard act to follow given the
surprise and fun nature of it, but Maskandi
musicians David Jenkins and Maqhinga
Radebe, who form the band Qadasi,
followed it with aplomb: great singing,
accomplished banjo and concertina
playing, and some foot stomping thrown
in for good measure. The audience loved
it and it was a fitting finale to a wonderful
evening and a great 2018.
The branch thanks all patrons and
table sponsors, ifm for the drinks
sponsorship, and Reed Exhibitors for the
gift hampers. David Jenkins and Maqhinga Radebe, Qadasi
 NICK DENBOW

Will UK industry pull out

of the Brexit torpor?
Whether the UK – whoever is in charge – decides
in March to remain in the EU, drop out, or
make a negotiated partial exit, the last year has
been disastrous for UK industrial investment in
instrumentation and control. Presumably this is
a result of the hold placed on investment across
most manufacturing industries, which has resulted
in a lack of new product releases. Possibly UK
businesses don’t yet know which way to turn, or
for that matter, which of their instrumentation and
control customers will survive.
European companies take a longer term
approach
The near two years of uncertainty for these
companies is a knock-out blow to the ultra-short
term approach of UK industry, where investors and
accountants rule and demand a one, or at most, two-
year payback from any expenditure. Possibly this is a
personal hobby-horse, but in Europe, particularly in
Germany and Scandinavia, companies and investors
think in much longer timescales. My normal example
of this is Endress+Hauser. Its output of PR and news is
much less frequent than possibly occurs with British
or US companies, but this has continued as previously
– these European companies are two years on from
when the UK paused for Brexit. E+H is continuing to
make investments for the future, outside the EU in
particular, which is surely what UK companies were
supposed to be doing, what Brexit was supposed to
achieve?
In November E+H announced the opening
of its new €3 million state-of-the-art calibration
and training centre in the industrial city of Jubail,
Saudi Arabia. Typically for E+H, the centre features
a classroom with interactive technology, an
extensively equipped workshop and a fieldbus
training laboratory. It offers practical, hands-on
training programmes designed to impart
knowledge on measurement technologies and
process control systems that are in demand by the
hydrocarbon, power and water and wastewater
industries. Subsequently, the Group announced
the appointment of Dr Andreas Mayr as COO, to be company failed to get UK Government backing.
responsible for all sales, production and support, At Wylfa in North Wales, a Hitachi nuclear plant
and effectively to be a deputy CEO to Matthias installation has started, with 33% funding
Altendorf. As ever, this is an internal, planned from Hitachi and each of the UK and Japanese
promotion. It also enables Altendorf to focus more governments. As the UK winter approaches, the
intensely on aligning, growing and strengthening Hunterston B number 3 nuclear reactor has not yet
the whole Endress+Hauser Group, which come back on line, after some cracks were found
particularly seems to mean internationally. in March. Instead of November, it will not return
to service till February. Currently unit number 4
UK government encouraging power projects is also offline, undergoing an inspection, and it is
There are some long-term investments made in ‘hoped’ this will return to power in mid-December.
the UK. However, these seem to be mainly financed Hopefully, the winter will not be too cold.
by government, or government guarantees. At Another useful government funded project was
Hinkley Point, the build programme for the EDF the White Rose Carbon Capture and Storage project
large EPR (European Pressurised Reactor), based at Drax power station. The Government withdrew
on the Areva (France) and Siemens (Germany) the funding some years ago. Now Drax has from its
design, continues. The long timescale of this own resources converted four of its coal fired boilers
build, based on past examples, will be extended to biomass (wood pellet) fuel.
significantly, and cost overruns will be inevitable. The UK is currently a partner in the £9Bn Galileo
The government deal will see the UK grid buying project, which is developing a modern version of
the Hinkley power at £92/MWh, whereas current a GPS system, specifically for military and security
offshore wind power is costing around £60/MWh. applications, but also with a lower resolution
Wind turbine developments continue apace, commercial system. The UK has invested £1,2 Bn so
and the latest offshore developments from far in this project, and has done most of the work
companies like Siemens in Germany are producing on the high definition aspects. But apparently the
realistic designs for 75 metre turbine blades, over European Union has decided that the UK will not be
twice the length of current wind turbine structures. allowed access to the high resolution information
These will inevitably result in a lower output cost available from Galileo, after Brexit!
for the grid companies. The next step will be to Apart from the government, there are some
have the turbines installed on moored floating private companies involved in long term investment
structures, rather than towers embedded in the sea projects in the UK. One notable example is BP, who
floor, enabling wind turbine offshore operations in has invested £4,5 Bn in oil and gas export facilities
many more locations around the world. from the Clair Ridge field, west of Shetland, in
The government has given some co-operation with Shell, Chevron and ConocoPhillips.
encouragement to the small modular reactor Oil has started flowing down a new 5, 5 km pipeline
concept, with money for design studies and to the Sullom Voe terminal, and will do so for the next
proposals: but not much concrete help or forty years. A gas pipeline has already been exporting
commitment. As a result of this, and other Group natural gas to Sullom Voe. Further drilling around the
problems in the USA, Toshiba (who acquired platform on the Clair Ridge field will continue for the
Westinghouse) have closed down its planned next ten years, to produce further wells.
NuGen nuclear reactor site in Cumbria, which was As for run of the mill projects, let’s hope that
the first of the planned ‘new nuclear’ modular some confidence can be resurrected, and that the
plants, after the rescue plan by a South Korean general C&I industry does regenerate soon.

Nick Denbow’s European report

Nick Denbow spent thirty years as a UK-based process instrumentation marketing manager, and
then changed sides – becoming a freelance editor and starting Processingtalk.com. Avoiding
retirement, he published the INSIDER automation newsletter for 5 years, and then acted as their
European correspondent. He is now a freelance Automation and Control reporter and newsletter
publisher, with a blog on www.nickdenbow.com

16 February 2019 www.instrumentation.co.za

 The authoritative one-stop resource for instrumentation,
systems and automation

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SA Instrumentation & Control leads to controlled decisions

 SYSTEM INTEGRATORS

System integrators
Abacus Automation

Abacus Automation supplies innovative, custom-developed

­technical solutions using standard PLCs, drives, scada and
motion control ­equipment and is Siemens approved for crane
automation. With 22 years in the industry, this award-winning
and ­internationally acclaimed company has highly qualified,
experienced and professional staff. It operates out of offices in
KwaZulu-Natal.

Tel: +27 31 702 5767

sales@abacus-automation.co.za
www.abacus-automation.co.za

Afrilek Altech Alcom Matomo

As solution providers in the industry, Afrilek’s extensive skills
encompass all aspects of electrical, control and instrumentation
design; implementation and operation. The company provides
complete automation and electrical solutions in projects, panel
manufacturing, support and services, training as well as product
distribution. Afrilek is a proud BBBEE, ISO 9001 and CIDB
accredited company.
Altech Alcom Matomo specialises in the design and supply of
turnkey communication systems such as wide area voice and data
networks and scada/telemetry solutions, as well as user terminal
supply and support. Backed up by highly experienced engineering,
project management, systems integration and field engineering
departments, these systems use products from the extensive
Motorola network range.

Tel: +27 11 372 9340 Tel: +27 11 235 7640

sales@afrilek.com nwatermeyer@alcom.co.za
www.afrilek.com www.alcommatomo.co.za

Autotronix Control Software Solutions - CSS

Autotronix is a recognised leader in industrial automation design and
implementation having attained its ISO 9001 certification. Autotronix
offers its clients turnkey control system integration services for energy
management, PLC/HMI/SCADA,VSD, manufacture of control panels,
applications for water distribution and manufacturing. The company
operates from offices in Gauteng and KwaZulu-Natal.
Tel: +27 31 705 0400
or +27 16 422 7644
sales@autotronix.co.za
www.autotronix.co.za
Customer-centricity allows CSS to attain a high percentage of repeat business
from its growing customer base. With a solid 16 years’ experience in designing
customised C&A solutions, CSS partners with customers in relationships
thriving on information sharing and open communication enabling them to
enhance customer operations. Supplier Certification provides customers with
the assurance that the CSS team is completely up to date on current trends
and technology as indicated by a number of prestigious awards.
Tel: +27 31 914 0040
pieterv@cs-solutions.co.za
www.cs-solutions.co.za

Hybrid Automation Iritron

Hybrid Automation is an approved Siemens system ­integrator and
partner for automation and drives, process instrumentation as well
as motion control. This enables it to provide its clients with the
latest technology and ­solutions. Its client base includes major blue
chip companies and has gained a strong foothold in virtually all the
engineering verticals.
Tel: +27 31 573 2795
info@hybridautomation.co.za
www.hybridautomation.co.za
Iritron is a new millennium technology company providing quality solutions
in the fields of electrical instrumentation and control systems engineering,
systems integration and simulations. It has a proven ability to manage projects
efficiently and produce high quality results. It has an extensive track record
of successfully implementing plant infrastructure reticulation, designs, and
automation and information systems. Iritron, a TUV accredited ISO 9001:2008
technology company, is able to offer its clients PLC, DCS and Scada software
and hardware, as well as electrical and instrumentation design, engineering,
project management and commissioning services.
Tel: +27 12 349 2919
alwyn.rautenbach@iritron.co.za
www.iritron.co.za

18 February 2019 www.instrumentation.co.za


Moore Process Controls
Moore Process Controls provides process automation and optimisation
solutions to realise the maximum potential of your plant and assets. Our
offerings include DCS, PLC, scada, compressor control solutions, MES,
production management and predictive maintenance systems, control
loop optimisation, alarm and energy management systems, plant security
and access management systems, Matrikon OPC, OSi Soft, dashboards
and historians, wireless and data solutions including digital twin, process
simulators and training simulators and cloud-based IIoT solutions.
Tel: +27 11 466 1673
info@moore.co.za
www.moore.co.za
Process Dynamics
Process Dynamics specialises in industrial automation and ­process control.
The company is one of Africa’s leaders in turnkey automation projects
and specialises in the integration of scada (WinCC, PCS7, Wonderware,
Citect) and PLC (Siemens, Schneider, Rockwell) as well as MCC and control
panel manufacturing and installation. Process Dynamics is ISO 9001:2015
accredited as well as a registered CIDB company.
Tel: +27 11 394 5412
systems@process-dynamics.co.za
www.process-dynamics.co.za
SAM – Systems Automation and Management
Systems Automation and Management is a supplier of data ­acquisition
systems and innovative automation solutions and is one of the l­eading
integrators of PLC, scada and fieldbus systems in South Africa. The
­company’s comprehensive range of capabilities includes industrial
networks, automation and control, scada, custom solutions, information
delivery, data warehousing, hardware and
software, BMS, MIS and MES.
Tel: +27 11 803 0570
info@sam.co.za
www.sam.co.za
SYSTEM INTEGRATORS
PCS Global
At PCS Global we understand that you’re ultimately in business to
maximise profits. This means reduced cost of ownership, increased
uptime, consistent results and ultimately a solution that not only fits
your budget but lets your business work whilst you’re at home with your
family. To us that means providing a hassle free, customised engineering
solution that exceeds your expectations. Are you ready to take your
business to the next level? We are! Level 2 BBEEE , ISO 9001:2015, CIDB.
Siemens, Schneider, Wonderware and Rockwell certified. Automation
Innovation, it’s the new AI.
Tel: +27 11 466 4172
sales@pcsglobal.com
www.pcsglobal.com
PSY International
PSY International specialises in industrial automation and ­process c­ ontrol. As
an approved ABB Authorised Value Provider for softstarters, VSDs and UMCs,
it guarantees supply of high quality and t­ echnologically advanced products
for energy measurement and monitoring. Its core competencies include
system integration; control panel building and commissioning; automation
design and supply; maintenance and breakdown service; PLC and scada
software development and building management systems.
Tel: +27 71 658 1553
paul@psy-intl.com
www.psy-intl.com
Saryx Engineering Group
Saryx Engineering Services offers complete solutions to
optimise plant-wide process control and enable operational
excellence and focuses on industries that require continuous
control for complex, business critical operations, including
mining, metals & mineral processing, chemicals, utilities/
water, but is equally comfortable with smaller non-critical
projects.
Tel: 086 099 5105
ingrid@saryx.co.za
www.saryx.com
www.instrumentation.co.za February 2019 19
Bag-in-Box technology just got faster
Beckhoff’s control architecture provides best solutions for local machine builder.
Founded in 2015, Pro Project Machinery
(PPM) is a bespoke machine building business
focusing its skills in the Bag-in-Box (BIB)
industry. Bag-in-Box, more commonly known
in South Africa as ‘papsak’ (boxed wine), is a
growing global industry and PPM makes up a
handful of expert machine builders who design
these complex machines.
The systems are diverse enough not only
to make bags for the wine industry i.e. 3 to
5 litres, but are in fact capable of producing
bags with a capacity of up to 250 litres. The
machines make either 1, 2 or 4 flexible bags per
cycle and are capable of running at 35 cycles
per minute. The bags themselves are made up
of 2 or 4 layers of material, drawn through the
machine and processed at different points.
Finally, a gland fitment is heat sealed into the
bag, after which a tap fitting is inserted into
the gland. The product is also heat sealed
laterally and horizontally, after which it is cut
and then manually packaged into boxes that
are delivered to various production facilities to
be filled.
PPM as a machine builder is passionate
about two elements on any project – using
cutting edge technology, and producing
equipment that lasts. All machines are
20 February 2019 www.instrumentation.co.za
drawn up in 3D CAD before manufacturing
starts and special care is taken when using
specialised parts and other componentry that
complements the machine.
In its quest to improve machine
performance and get ahead of the
competition, PPM partnered with Beckhoff
Automation, a leading automation company,
to provide the control components for
its machines. Beckhoff’s knowledge and
experience in the field of motion control have
proven an invaluable accompaniment in this
regard.
PC-based control and EtherCAT fieldbus
support a fast automation architecture
“The first step was undertaking an in-depth
analysis of existing machines in the industry
and identifying their performance weaknesses,”
explains PPM technical director Gareth
Schenck. “One of the obvious problems
that had to be addressed was the issue of
pneumatic cylinders. An average 4-lane
machine could use as many as 60 50-bore
cylinders, consuming up to 5000 litres of
compressed air per minute during operation.
“Replacing these with servo driven electro
mechanical cylinders (EMCs) was an inviting
alternative. EMCs provided solutions to many
existing machine shortcomings in these
types of machines, from eliminating the need
for large auxiliary compressors, to being able
to control the accuracy of sealer bars within
micrometres, giving more consistency to the
quality of the end product.”
Based on this line of reasoning, the
final machine design included a total of 64
servo motors and drives. This posed two
problems for the control design team: first,
was there an available control system that
could simultaneously provide full 64-axis
motion control from one unified controller?
And second, was there a control network
capable of providing the sub 2 ms data
transmission times required for accurate
machine control?
Beckhoff Automation answered both
questions. “Using our PC-based control
approach, a CP 6930 industrial PC with
multicore Intel® i7 processor easily handled
all the motion control requirements.
Secondly, the speed of the purpose built
EtherCAT network made seamless integration
between all 80 of the EtherCAT nodes viable,”
explains Dane Potter, a sales engineer from
Beckhoff’s Cape Town office.

Overall system improvements
“The tapping insert station, which was transformed from pure
pneumatic processes to 4x4-axis motion controlled pick and place
using industrial camera imaging to detect defective fitments, as well
as orientation, made on-the-fly fitment placing a dream to implement,”
outlines Schenck.
“In addition, Beckhoff ’s TwinSAFE safety PLC made the often
painful integration of safety and control an easy task,” adds Potter.
“With eighteen light curtain zones, three safety scanners, twenty-two
electromagnetic door sensors, and twenty-four guard sensors, the
machine is extremely benign, giving reassurance to operators and
maintenance personnel alike that it is safe to work on.”
TwinCAT PLC HMI in conjunction with the 21.5” Beckhoff CP Panel
made machine visualisation effortless to implement with its 1080p
graphics. This coupled with TwinCAT PLC HMI Web made the ability to
view machine metrics on mobile devices uncomplicated and intuitive.
Also, PPM utilised the latest AX8000 Servo series, which was not only
easy to install and connect due to its modular One Cable Technology
(OCT) design, but the built-in FPGA chipset made force feedback
extremely accurate.
A large 50” screen at the front of the machine gives personnel a
good overview of machine performance, as well as showing warnings
to machine operators and packers – a great value add to the machine.
Benefits realised
Using this fast motion control capability, the web speed and sealer
bar positions were easily synchronised to achieve maximum machine
performance. Also, the decision to use EMCs, which exert far more force
than their equivalently sized pneumatic counterparts, resulted in the
benefits of faster sealing times, improved machine speed and greater
production accuracy. (Machine performance increased from a previous
maximum of 7680 bags per hour to a never-before-achieved 8400 bags
per hour.)
One of PPMs top customers had this to say about a newly-delivered
machine: “The ease of use far exceeds that of any bag maker we’ve had
before, and the quietness of the servo actuation also makes for a very
pleasant work environment. In monetary terms, we appreciate the fact
that running costs have decreased by 60% due to not needing the large
amounts of compressed air required previously. We look forward to the
improved production capabilities this new design affords us.”
COVER STORY
The C6930 control cabinet PC combines everything a cutting-edge
industrial PC requires in a compact aluminium housing: a Beckhoff
3.5-inch motherboard designed for Intel® Celeron® or Core™
i3/i5/i7. In this case the i7 was used, a wide range of PC interfaces,
up to three Ethernet ports e.g. for EtherCAT-based controllers and
optional fieldbus interfaces for conventional bus systems. It also
features an on-board RAID controller for mirroring two hard disks,
which can be used for convenient configuration of RAID applications
supported by the TwinCAT automation software. In addition to or
instead of the hard drive, a flash disk can be integrated in the form
of a Compact Flash card (CF) or a solid-state disk (SSD). The result is
high data security that can be enhanced further through optional
UPS functionality.
Two free plug connector panels installed ex-works are provided
for additional interfaces such as RS-232, sound and two additional
USB ports. Optional fieldbus interfaces e.g. for Profibus, CANopen,
DeviceNet, Profinet and Ethernet IP, while a third Ethernet port or
a non-volatile memory module for fail-safe storage of process data
can be connected via a mini PCI slot. The compact C6930 control
cabinet PC is ideally suited for application as a central controller in an
EtherCAT-based control system. It is equipped with two standard and
an optional Ethernet port and offers optimum performance for all
EtherCAT control tasks.
“Machine performance increased from
a previous maximum of 7680 bags
per hour to a never-before-achieved
8400 bags per hour.”
On future machines, PPM will seek to automatically move machine
units to facilitate quick and easy setup,” concludes Schenck. “Load cell
technology will also be added to bring even greater accuracy to the
material sealing aspects.”
For more information contact Michelle Murphy, Beckhoff Automation,
+27 11 795 2898, michellem@beckhoff.com, www.beckhoff.co.za
www.instrumentation.co.za February 2019 21
 FOOD, BEVERAGE & PHARMACEUTICAL
Improved supply chain efficiency and
energy saving at Namibia Breweries
Established in 1920, Namibia Breweries is one of
the leading beverage manufacturing companies
in Namibia and southern Africa. Today, with the
stated vision to be the ‘most progressive and
inspiring company’, NBL leads the domestic
beer market and has a significant share of the
premium beer category in South Africa.
While the company’s main focus is
producing beer, its other portfolios include soft
drinks, fruit juice and water using raw materials
such as malt, hops and water. NBL’s notable
achievements include energy saving projects
such as the biomass boiler, on-site solar plant,
and personal boreholes, as well as winning
10 consecutive gold medals at the Deutsche
Landwirtschafts-Gesellschaft (DLG) Quality
Evaluation Awards. NBL has also managed to
double its production output on average every
10 years over the past three decades.
To keep this momentum going, the
integration of MES with ERP systems and other
business applications has become mission-
critical for plant operations. It enables agile,
short-term production planning and flexible
update schedules and improves supply chain
visibility and decision support by updating
business applications with production
responses in real time.
Access to real-time, centralised
information
NBL MES specialist Annemarie Kruger
explained: “From a process perspective, NBL
had a challenge when it came to sending real-
time process orders automatically to its ERP
system, versus sending a process order that
needs to be verified by human interaction first.
“These time delays, as well as having
22 February 2019 www.instrumentation.co.za
too many different sources of information
and systems, led to our malt orders, a key
ingredient in the brewing of beer, not being
generated correctly. The result of this is a
potential situation where not enough malt is
delivered on time, meaning the business may
have to stop production at times. Production
loss in brewing can cost the organisation more
than NAD one million per day.
“Alternatively, too much malt could be
delivered on site due to an incorrect order
placement. This type of error has resulted
in an estimated NAD two million loss in
demurrage fees over the past year due to
delayed operations in unloading. In order to
avoid these predicaments, NBL decided to roll
out Wonderware Enterprise Integrator and
Wonderware Skelta BPM.”
“NBL has improved its
efficiency by providing a
platform where business-
critical information is
captured and stored in a
central location.”
Wonderware Enterprise Integrator
Wonderware Enterprise Integrator enables
message exchange and automatic data
synchronisation between multiple business and
plant applications. It is a commercial off-the-shelf
software that allows business and manufacturing
systems to complement each other, in a loosely
coupled yet highly reliable manner.
Wonderware Skelta BPM
Wonderware Skelta BPM helps organisations
perform intelligently, effectively and in a
governed manner. Through its powerful
functionality and model-driven framework, this
solution offers a strong platform for effective
modelling across the enterprise for improved
productivity and rapid delivery of new
business applications.
One centralised location, one version of
‘the ‘truth’
The combination of the two solutions has
allowed the brewing company to integrate
its PCS and ERP systems, putting the correct
system-related controls in place and ensuring
that logistics and procurement staff can use
current (near real-time) information, with
less manual intervention, in order to plan
accurately for the next malt and raw material
shipment. As well as ensuring data integrity,
all of the people, processes and systems within
the organisation that need access to this
information can retrieve it from a single source.
“We are now one step closer to becoming
a fully functional ‘single version of the truth’
business through the use of these Wonderware
products to integrate our ERP system with
the plant control solutions,” concludes Kruger.
“NBL has improved its efficiency by providing a
platform where business- critical information is
captured and stored in a central location.”
For more information contact
Clarise Rautenbach, IS3 – Industry Software,
Solutions & Support, +27 11 607 8473,
clarise.rautenbach@is3.co.za,
www.is3.co.za
www.instrumentation.co.za February 2019 23
 FOOD, BEVERAGE & PHARMACEUTICAL
Conveyor systems for grain applications
BLTWorld offers dependable solutions for
specific problems at the transfer points of
conveyor systems in bulk materials handling,
for example, grain in the food and beverage
industry.
“ScrapeTec Trading’s German-engineered
products have been specially developed for the
prevention of dust formation and material spill,
and for more efficient belt cleaning at critical
sections along the conveyor route and transfer
points,” says Ken Mouritzen, managing director,
BLTWorld, distributors for ScrapeTec Trading in
Africa and the Indian Ocean Islands. “AirScrape,
DustScrape and SpeedScrape systems, which
are easy to assemble and operate, form an
important part of our custom-designed
solutions service, to meet exact bulk material
conveyor project requirements.
“Correct installation of suitable equipment
ensures cost efficiency, optimum performance
and safety, reduced risk of breakdown and
extended service life of the conveyor system.
The DustScrape dust filter system, which is
used in conjunction with the contact-free
AirScrape conveyor belt skirting system,
provides an effective, energy-free dust
emission prevention solution. The compact and
lightweight system complies with most new
dust prevention guidelines and prevents health
and safety issues on-site. It also minimises
product loss, by effectively preventing material
Advanced sugar technology from Bosch
With 55 years’ experience in the sugar sector,
Bosch Projects offers a comprehensive
service globally, which encompasses strategic
planning and feasibility studies, sugar
technology development, project structuring
and funding, as well as plant design and
engineering, project delivery, operational
support and training.
The company designs and supplies a
full range of sugar processing equipment,
from front-end cane preparation and juice
extraction, through to sugar production.
“The company has recently developed
the Lamella Clarifier, which utilises a series
of inclined plates for fast, effective particle
separation and settling,” explains Steve
Rosettenstein, sector director, sugar, Bosch
Projects. “Our research and development
department, which is constantly improving
efficiencies of existing equipment and
developing new systems, has designed the
Lamella Clarifier especially for the sugar
24 February 2019 www.instrumentation.co.za
from being blown into the surrounding
environment.”
DustScrape consists of a durable filtering
cloth that is installed above the conveyor
belt, to retain dust particles, while remaining
permeable to circulating air. This long-lasting
filter cloth is available with different qualities
for specific applications, e.g. grain transfer.
The DustScrape system comprises a filter
cloth, support arches and skirts, arms to
hold the system above the belt and a rubber
curtain to eliminate further dust development
– all sized to specific requirements. It is easy
to install and can be retrofitted to existing
conveyors for continuous or periodic operation.
industry, to satisfy a demand for short retention
clarification.
“Although various clarifier systems are well-
established in water treatment applications, this
technology is new in sugar processing and is
especially effective for juice, syrup and refinery
phosphation clarification. The Bosch Projects
system is smaller than conventional clarifiers
and substantially reduces liquor retention times.”
The design of this new settling clarifier
reduces the size and footprint of conventional
juice clarifiers by approximately 30%,
significantly lowering capital investment costs.
Important features include short residence
times, reduced sucrose degradation and
improved turbidity removal. This highly efficient
system, which operates with no moving parts,
requires minimal maintenance.
The syrup clarifier is similar in design to
the juice version, except that it operates as a
flotation clarifier, as opposed to settling. This
unit is particularly attractive for clients who
Selection of the correct AirScrape size
depends on the loading width of the conveyor
belt and the required load-free zone of the belt
edges. The AirScrape conveyor belt skirting
system is installed above the load-free zone
and generates the air-intake from outside,
into the system. The generated airflow from
above the conveyed material then gets filtered
through the filter cloth, retaining any dust
particles which are re-deposited back into the
material flow.
For more information contact Ken Mouritzen,
BLTWorld, +27 31 274 8270,
ken@bltworld.com, www.bltworld.com
require improved sugar quality, with a lower
investment cost.
The syrup lamella clarifier can be switched
on and off as desired when syrup qualities
are low and it can be easily installed inside an
existing factory, due to its relatively small size, in
comparison with a conventional syrup clarifier.
It has all the other advantages of its juice
counterpart.
The Bosch Projects team works closely
with its technology partners and various
fabricators throughout the world, to ensure
the manufacture of all equipment adheres to
stringent international quality standards and
exact design specifications. The company has
an extensive network of offices in Africa, South
and Central America and the United Kingdom.
For more information contact Melanie
Elsworth, Bosch Holdings, +27 31 535 6192,
elsworthm@boschholdings.co.za,
www.boschholdings.co.za

Infrared technology
in the food and
beverage industry
Keeping production strictly on schedule
in any facet of the food and beverage
industry, whether it be pumps, conveyors
or electrical connections, means
downtime is not an option. Comtest
advocates including infrared inspections
(IR) into the maintenance mix. Its range
of high performance, thermal imagers
makes year-round spot-testing possible,
onsite, specifically troubleshooting
and monitoring transformers, switches,
disconnects and MCCs; pumps, motors
and compressors; valve operation;
tank and sludge levels; level control
performance; pipe blockages and
integrity; operating temperature;
conveyors and roller bearings; boilers and
chillers; HVAC, and roof moisture, air leaks
and insulation issues.
By performing quick infrared spot
checks, maintenance technicians can
uncover potential failures, thus allowing
for timeous, repairs when convenient.
Thus the line can be kept moving through
frequent scanning and troubleshooting
of critical equipment. Traditional
troubleshooting using trial and error can
be effective, but time consuming and
costly. What is critically important is to be
able to pinpoint an issue within a mass
of sprawling production lines, quickly,
because downtime is expensive.
Equipment cost has historically forced
plant managers to outsource annual
infrared inspections, and in many cases,
limit the scope of work. Annual scans
certainly uncover problems, but users
should not have to ‘hope for the best’
until next year’s scan. Food and beverage
production demands reliability, so yearly
spot checks are no longer enough.
Regular production line monitoring
can narrow down and rule out possible
problem causes faster by picturing the
situation in infrared, allowing the varying
temperatures of components to ‘tell the
inside story’.
Quick tips for performing successful
IR inspections:
1. Ensure consistent frequency: infrared
inspections of all major components
and connections should be performed
at least bi-annually.
2. Adjust for emissivity: components and
materials emit energy differently. For
accurate findings, ensure that the
proper emissivity setting is being used
for the material that is being inspected.
Also, consider altering the surface
by adding tape or paint to increase
emissivity.
3. Perform qualitative measurements: compare
findings with similar components and
connections under similar conditions to
reveal thermal anomalies.
4. Ensure safety during inspection:
beyond electrical safety, be careful
not to neglect the surroundings while
performing infrared inspections.
Focusing too heavily on the thermal
imager can distract the personnel from
rotating, cutting, or other dangerous
equipment.
For more information contact Comtest,
+27 10 595 1821, sales@comtest.co.za,
www.comtest.co.za
FOOD, BEVERAGE & PHARMACEUTICAL
Quarter-turn
actuator for
harsh conditions
Thanks to its versatility and flexibility, Festo’s quarter-turn
actuator DFPD can be used in a variety of applications. Its
modern, simple and compact design impresses whether
it is used with ball valves, shut off valves or air dampers
in the pharmaceutical or beverage industry or for water
treatment and other areas of process automation.
Flexible in operating pressure
The single-acting version of the new actuator is
particularly compact and extremely modular. Due to
its optimised design it can be configured in increments
of 0,5 bar for more effective use. With nine different
spring combinations, the DFPD meets the most precise
operating pressure requirements between two and six
bar. The rotation angle for the standard size is up to 90°
and for the sizes 40, 120, 240 and 480, it rises to 180°.
The basic version of the DFPD is suitable for
temperatures between -20 and 180°C. The low
temperature variant is designed for arctic regions and
covers a temperature range of -50 to 60°C. The high
temperature variant can be used at temperatures
between 0 and 150°C. With its versatile and corrosion-
resistant surface coating, the actuator can also be reliably
and flexibly used in harsh conditions. It can be mounted
anywhere and the end positions can be adjusted, both
ends enduring high flexibility during operation.
A complete package covering the entire value chain
In combination with the CMSX positioner, the actuator
is suited for analog control in dosing tasks. Furthermore,
the sensor boxes SRBC/SRBE/SRBG enable simple digital
control and full position sensing, which is possible
outdoors as well as in potentially explosive environments.
For more information contact Kershia Beharie,
Festo, 086 003 3786, kershia.beharie@festo.com,
www.festo.co.za
www.instrumentation.co.za February 2019 25
 FOOD, BEVERAGE & PHARMACEUTICAL
The next level in dairy applications
Reliable and repeatable tank level measurement proven with 80 GHz technology.
The South African consumer landscape has
changed dramatically over the last decade.
Characterised by a rapidly growing middle class,
and an increase in demand for high quality
consumer packaged goods (CPG), coupled with
stringent legal requirements for food safety,
food and beverage manufacturers are under
tremendous pressure to optimise their processes
to deliver high quality, cost-effective products to
discerning customers. Customer centricity now
dictates the nature of manufacturing, moving
away from the traditional prescriptive mindset
that dominated the industry.
A well-known South African beverage
company with a long and successful history
in the growth and development of the local
dairy and fast-moving consumer goods (FMCG)
industries recently faced an engineering
challenge in optimising its mixing process.
Its presence in the beverage sector has been
entrenched by winning several taste and quality
accolades, as well as being voted the most
reputable company in South Africa a few years
ago. With an enviable basket of established
brands and a requirement for frequent change-
overs, product losses were becoming both a
financial burden and a looming impact to the
environment.
Taking pride in ensuring that the
increasing costs associated with stringent
safety and quality requirements are not
merely passed on to the consumer, this
organisation drives process optimisation and
resource savings as a corporate culture at all
manufacturing facilities. The maintenance
managers deliberately focus on improving
overall plant reliability without compromising
26 February 2019 www.instrumentation.co.za
on product quality – key to meet the stringent
requirements related to food safety.
As a socially responsible organisation,
meticulous detail to plant optimisation is not
merely due to the focus on reducing factory
losses, but aims to limit the effects of total
organic carbon (TOC) and chemical oxygen
demand (COD) that impact the environment.
Better accuracy required from level
transmitters
The performance of the existing level
transmitters was unsatisfactory, requiring
improved accuracy with a reliable and
repeatable measurement from the new devices.
This installation involved turbulence, tank
intrusions, an agitator and a degree of foaming
in a vessel with a conical base. The capacitance
type probes did not measure accurately to the
bottom of the mixing tanks, which resulted in
product being left behind when transferring
to the buffer tanks. The net effect of this
measurement problem resulted in product loss
and high effluent costs.
Endress+Hauser was approached to support
this application with a trial unit, along with other
competing suppliers. This was an opportunity to
showcase the unique performance capabilities
of the company’s 80 GHz free space radar level
transmitter. The FMR62 was offered to the
customer, and a defined assessment matrix
was developed. Three test units from different
manufacturers were run on the mixing tanks
and assessed on the following criteria:
• Process fit and integration.
• Ease of use.
• Service and support.
• Performance.
• Total cost of ownership.
The solution provided by Endress+Hauser
performed the best overall, delivering the
highest score in the above evaluation. The
accuracy demonstrated by the unit even
allowed the customer to determine minimal
levels that accumulated in vessels during
cleaning in place (CIP) operations. This offered
a new degree of traceability from a single trend
if a CIP has been carried out between batches.
When reviewing the results post-trial, the
factory’s maintenance manager emphasised
that he was extremely impressed with
Endress+Hauser’s level transmitter’s accuracy
at low levels. His initial assumption was that the
level transmitter was drifting at the zero point
after the tank was emptied. But, upon closer
inspection, it became evident that the FMR 62
was detecting the residual from the sidewalls
that was pooling in the vessel cone.
None of the other trial devices had revealed
this inherent process condition. He further
commented that this was excellent accuracy
in the most difficult part of the tank (cone).
The accuracy delivered was better than he
had hoped for and this could aid operators to
ensure tanks are truly empty before starting a
new batch. This positive feedback has resulted
in the site planning a migration strategy
for their mixing tanks that will leverage the
technology benefits of the FMR62.
For more information contact Anban Pillai,
Endress+Hauser, +27 11 262 8000,
anban.pillai@za.endress.com,
www.za.endress.com
www.instrumentation.co.za February 2019 27
Large German fertiliser manufacturer
reduces costs thanks to SICK Automation
Available agricultural land in Europe is
limited. As a result, large quantities of
fertiliser are used in order to increase yields.
Producing fertiliser, however, is an energy-
intensive process which requires monitoring.
One of the largest fertiliser manufacturers in
Germany chose to use technology from SICK
Automation, which includes the installation
of over 100 analysers in existing plants.
SICK also developed a self-cleaning
in situ measuring probe for reliable gas
measurement in environments with wet
dusts. Specific monitoring during the
processing of phosphate rock and the
production of sulphuric acid and phosphoric
acid was required. The technology also
had to be capable of monitoring processes
during the manufacture of mono and
diammonium phosphate (MAP/DAP). Until
recently, the technology used to measure
the gas and dust emissions did not always
deliver reliable results.
Technology deployed
Processing of phosphate rock
In most cases, SICK has tried and tested
products available ideal for the task at hand.
With regard to the processing of phosphate
rock, the company needed a product to
28 February 2019 www.instrumentation.co.za
monitor SO2, NOx, CO, and CO2 as well as
dust loads at the outlet of the rotary kilns.
The solution had to be able to provide
reliable and accurate measurements even
in the presence of fine dusts. The GM32 in
situ gas analysers were provided for SO2 and
NOx, the GM35 for CO and CO2, along with
the Dusthunter SP100.
Sulphuric acid production
In the case of sulphuric acid production, the
solution had to be able to monitor SO2 and
O2 emissions from the stack. In this case, the
best choice was the MCS300P HW multi-
component analyser system, which requires
significantly less maintenance due to its
hot/wet extractive measuring technology.
Fluoride
As phosphate rock contains fluoride,
HF is released during the production of
phosphoric acid and is washed out in
the wet scrubber. In order to monitor the
performance of the scrubber, HF levels need
to be measured on the stack. This task was
taken on by the GM700 laser gas analyser,
which has a proven track record in the
measurement of aggressive and corrosive
HF.
Dust emissions, NH3 concentrations and HF
emissions
These tasks proved to be a major challenge
as the humid, aggressive, and dusty process
media made it difficult to take continuous
measurements. The chosen solution in this case
was the GM700 in situ gas analyser combined
with the FWE200 extractive dust measuring
device. SICK developed a special measuring
probe for the GM700 which cleans itself
periodically. The solution can withstand the
high levels of salt formation and significantly
reduces maintenance. As a result of the
continuous monitoring, the excess ammonia
in the process can also be cut considerably.
The final step was to install eight FWE200 dust
measuring devices at one of the sites.
The customer’s key requirements were
greater plant safety, fewer failures, lower
operating costs, and access to real-time
production data. Thanks to SICK Automation’s
leading technology, this was achieved and
preparations are already under way for a
second site.
For more information contact Mark Madeley,
SICK Automation Southern Africa, +27 10 060
0550, mark.madeley@sickautomation.co.za,
www.sickautomation.co.za

Traceability for tobacco manufacturer
SICK Automation South Africa recently installed
120 image-based 2D barcode readers across
multiple scanning stations in a South African
tobacco manufacturing plant. The cigarette
manufacturer was looking for a solution to
move from its manually intensive marking and
tracing system, which facilitated human error
and lacked a satisfactory verification process, to
a modern technological one.
The client’s objective was to ensure the
plant retained its ability to produce world-class
products. This would be achieved through
increased product traceability and improved
quality control. SICK recommended its Lector
620 Professional image-based barcode readers,
part of the Lector 62x product family, specifically
designed for improved product and process
traceability.
The installation of these barcode readers
has ensured that the plant has technologically
up-to-date unit level traceability on all product
elements. This extends from the container-
stored tobacco blends through the entire
production process, ending with the cartons
of cigarette boxes contained in palletised
containers for distribution. The Lector 620
range includes a fail-safe microSD card in case
of device failure, which automatically loads all
required device settings when inserted into a
new device.
“Traceability allows for safe products
to be manufactured while protecting the
Hygienic limit switches for processes
Process and storage vessels incorporate
limit switches to prevent overfilling of a tank
or vessel (full indicator) or dry running of a
pump (empty indicator). Anderson-Negele’s
NCS series are ideally suited for the reliable
measurement of limits in media with low water
content, such as certain alcohols and cosmetics,
providing universal application in bottling and
pharmaceutical applications.
Capacitive working principle
Anderson-Negele level switches operate on
the basis of the capacitive working principle.
The measuring electrode, the medium and the
conductive wall of the tank form an electrical
capacitor influenced by three main factors:
distance; area of the electrode surfaces; and
type of medium between the electrodes.
The measuring electrode and the tank wall
serve as the capacitor plates while the medium
production process,” points out Mark Madeley,
marketing manager, SICK South Africa. He
adds that among the benefits of the Lector
620 Professional is the automatic parameter
switching ability. “This allows the barcode reader
to change its settings between four different
modes, thereby accommodating variances
in lighting conditions.” The software used can
also artificially enhance the barcode to ensure
the highest possible read rates and its image
capturing ability conducted simultaneously to
scanning is another advantage. “No-read images
are saved, providing our client with the ability
to diagnostically ascertain the cause of the fault
and implement timeous remedial action,” adds
Madeley.
All devices were pre-programmed according
to the manufacturer’s standards with the
acts as the dielectric fluid. Due to the higher
dielectric constant of the medium relative to
air, the capacity increases when the electrode is
immersed in the medium. Exposing the electrode
has the opposite effect. The change in capacity
is analysed by the level switch and converted
to a corresponding switching command. The
sensor outputs a 24 V DC signal (active output).
PACKAGING & BOTTLING
plant’s maintenance engineers receiving device
competence training.
Used in the packaging and pharmaceutical,
automotive, electronics and solar industries as
well as the document handling industry, the
Lector 62x family decodes all common 1D, 2D
and stacked codes and has optical character
recognition. They come standard with industrial,
compact housing with swivel connector; flexible
interfaces; and microSD memory card, while
the function buttons include aiming laser, focus
adjustment, auto-setup and greed feedback
LEDs.
For more information contact Mark Madeley,
SICK Automation Southern Africa, +27 10 060
0550, mark.madeley@sickautomation.co.za,
www.sick.com/za
The minimum and maximum (full/empty)
switching functions can be swapped by
reversing the polarity of the power supply.
The capacitive working principle requires
that the sensor tip, which is made of PEEK,
be completely immersed in the medium.
The advantage is that the sensor does not
respond to foam or adherences and a signal
is emitted only when the medium reaches
the level. Capacitive measurement is most
reliable when the dielectric conductivity and
temperature of the medium are constant.
Changes in the outer conditions are generally
non-critical in media with high dielectric
constant values.
For more information contact
Morton Controls, 086 100 0393,
sales@mortoncontrols.co.za,
www.mortoncontrols.co.za
www.instrumentation.co.za February 2019 29
 PROCESS MEASUREMENT
Hygienic flow measurement
Compact stainless steel sensor for conductive and non-conductive liquids.
Intelligent solutions for level, temperature,
flow, and pressure measurement from SICK
Automation’s product portfolio are proven
to meet the stringent requirements for
safety and hygiene in the food and beverage
industry. The portfolio contains a new flow
sensor that uses ultrasonic technology to
determine the flow volume of conductive and
non-conductive liquids in hygienic and highly
demanding environments.
Selecting the right method and
appropriate device for the flow measurement
generally involves resource intensive
consideration of the advantages and
disadvantages of the different systems and
measuring methods. Particularly in the
food and beverage industry, which relies on
high process reliability and perfect hygiene
standards, this means that there are often
a large number of different measuring
devices for the respective production areas.
Therefore, the industry welcomes instruments
that reliably monitor the flow of drinking
chocolate, beer, olive oil, demineralised
water or milk, and which are just as precise
in measuring the flow of cleaning agents in
CIP and SIP plants, or cooling water in cooling
circuits. This variety of applications is possible
thanks to sophisticated ultrasonic technology.
The Dosic ultrasonic sensor operates
according to the concept of time-of-flight
difference: If the ultrasonic signal is sent
against the flow direction, it requires a
longer transit time than the signal sent in
the direction of the flow. The transit-time
difference between the two ultrasonic signals
is directly proportional to the mean flow
30 February 2019 www.instrumentation.co.za
velocity. With regard to reliability and precision
in transit-time difference measurements, the
sensor can detect a wide range of challenging
liquids and media for beverage and food
production, irrespective of their properties.
Durable and reliable in hygienic
conditions
The rugged and compact model combined
with a hygienic design ensures highly reliable
measurement results. The absence of moving
parts in the sensor eliminates potential
contamination risks in the demanding hygienic
environments of the food industry. In addition,
the sensor has a straight, seal-free and self-
emptying measuring tube made of high-
quality stainless steel. The sensor has EHEDG
certification and demonstrates FDA conformity.
Since there is no contact between the sensor
and the flowing media, and the flow volume
is determined in a non-contact manner,
aggressive cleaning agents in CIP and SIP
operations are not a problem either. The sensor
can easily withstand temperatures up to 145⁰C
in SIP processes for up to one hour. The rugged
design ensures a long service life and reduces
the need for maintenance.
Compared to similar flow sensors that
take up a lot of installation space, the Dosic
can be used in the most confined spaces. Two
configurable digital inputs and outputs and
up to two analog outputs, as well as an IO-Link
interface reduces cabling and also enables
complete control and monitoring of the sensor
in Industry 4.0 machine environments.
It is not necessary to set special parameters
before the measurement process. If the
medium is changed, the sensor automatically
adjusts its parameters accordingly. This ‘plug &
measure’ solution eliminates the need for initial
medium calibration and reduces installation
and operating costs. The Dosic is a flexible
measurement system available in two sizes:
DN15 and DN25.
In addition to the flow sensor, the extensive
SICK portfolio contains other sensors that
are ideal for hygienic application conditions.
For example, the PHT pressure transmitter
ensures constant liquid pressure in buffer
tanks when bottling carbonated beverages.
The PHT controls the pressure precisely at
high throughput rates, even when pressure is
applied to bottles and cans to prevent foaming.
The PBS hygienic pressure switch is also
designed for hygienic pressure measurement
and monitoring. It is used in bottling
machines, particularly for the hydrostatic
level measurement of liquids in tanks. The LFP
Inox, which has been developed especially for
the high demands of the beverage and food
industry, measures the fill levels as well as the
limit levels in buffer or machine tanks. Thanks
to its high-end design and variant diversity, it
provides the ideal prerequisites for a number
of application possibilities. Thanks to the foam
mode, the LFP can easily be used even in
difficult applications such as bottling foaming
liquids like milk.
For more information contact
Robert de Scánde, SICK Automation Southern
Africa, +27 11 472 3733,
robert.descande@sickautomation.co.za,
www.sickautomation.co.za

A new standard for digital
­inclination measurement
A new standard for digital inclination
measurement has been set with the
latest digital protractors from Stabila.
Both the Tech 500 DP and Tech 1000
DP are manufactured exclusively in
Germany, the main difference being that
the Tech 500 DP measures from 0° to
90° and 90° to 0°, while the Tech 1000
DP covers 360°. The former reveals what
is out of sync, while the latter calculates
the exact amount.
In addition, the Tech 1000 DP
features data transmission to peripheral
devices via the RS-485 interface with a
ModbusS documentation protocol and
Stabila Analytics software for analysis. It
includes a USB data cable with an M12
connector and a four-pin data cable
with M12 connectors. This makes it
well-suited to the automotive industry,
where, for example, it can be used
to align radar systems on new motor
vehicles.
PROCESS MEASUREMENT
Digital float
switch
As its first instrument of this kind, WIKA has launched a
float switch with a PNP/NPN output signal. The model
GLS-1000 detects the level of liquids with an accuracy of
1 mm or less.
The digitised float measuring principle of the new
level switch is implemented using semiconductor
sensors, which enable an unlimited number of switching
cycles. Users can define up to four switch points with a
minimum distance of only 2,5 mm. Thus the instrument
reacts to even the smallest changes in level. At the same
Long-term measurements are also
time, the GLS-1000 can monitor the temperature of the
possible, thanks to a range of mounting
medium via a temperature output with a Pt100/Pt1000
options. These include a T-groove and a
resistance.
V-groove, plus an integrated rare earth
Even with the electronic circuitry, the digital float
magnet. The Tech 500 DP can also measure
switch is also an economical measurement solution due
key values in quality assurance, while
to its similarity in design to its conventional counterpart.
it allows for easy alignment of systems
With the GLS-1000, traditional PNP/NPN limit level
during the commissioning of special-
switches can now also be replaced by a float switch.
purpose mechanical engineering tasks.
The latest digital protractors from
Stabila make for easy measurement
and alignment tasks in a broad range
of applications. The Tech 500 DP is ideal
for production applications such as
maintenance on or setup of machines,
while the Tech 1000 DP allows the
digitisation of existing production
machines for monitoring purposes.
For more information contact
Alison Thomet, Upat SA, +27 11 624
6700, alison.thomet@upat.co.za, For more information contact WIKA Instruments,
www.upat.co.za +27 11 621 0000, sales.za@wika.com, www.wika.co.za
www.instrumentation.co.za February 2019 31
 PROCESS MEASUREMENT

Bromide sensor for water disinfection

With the expansion of its product range of membrane-covered
amperometric digital sensors for liquid analysis, ASSTech now has
available the Jumo tec-Line Br bromide sensor for general water
disinfection applications.
Bromide is a halogen that is exceptionally well-suited for
disinfecting aqueous media and is effective against bacteria, viruses
and fungi while at the same time removing pollutants in water
through oxidation. The disinfection effect is only slightly weaker
than with chlorine. Bromide has a high pH tolerance and, in contrast
to chlorine, still works very well at pH values around 8.
The new Jumo tecLine Br sensors distinguish themselves
through a proven measuring system, easy calibration and integrated
temperature compensation. A digital interface allows the new
sensor to be integrated into the Jumo digiLine analysis sensor
network.
Measurement, dosing and recording devices for bromide can be
found in the Jumo Aquis touch S and P controller families as well as
the Jumo mTron T automation system. The sensor variant with
4-20 mA can also be connected to the Aquis 500 AS or Jumo
dTrans AS02 devices.

For more information contact Anastas Schnippenkotter,

ASSTech Process Electronics & Instrumentation, +27 11 708 9200,
info@asstech.co.za, www.asstech.co.za

32 February 2019 www.instrumentation.co.za

 PROCESS MEASUREMENT

Effective level sensors

Val.co offers a range of affordable and effective level sensors that have applications
across all sectors of industry, but that benefit, in particular, the tank building
sector. The range includes small float switches, Linear-LC, limit level switch for side
installation, simple or double contact limit level switches, and multipoint devices.
“Val.co has a proven track record of more than 30 years of experience in
the process instrumentation field,” commented GHM Messtechnik South Africa
managing director, Jan Grobler. “The company is dedicated to designing process
instrumentation that satisfies customer requirements and the quick turnaround
from design to customer prototype is one of its strengths.”

Five ranges
Affordable small float switches for lid or bottom installation for industrial use are
available in brass, stainless steel, polypropylene, PVC and PVDF. Combinations are
available for use under aggressive conditions and have parallel or conical thread
connections.
A comfortable continuous measurement based on proven float technology
is offered by the Linear C range. An integrated Reed chain with resistance circuit
enables continuous level monitoring. Switching of tube lengths up to 2000 mm
enables affordable electronic measurement in large tanks. The Omni-LC digital
indicator offers the possibility of displaying measurements locally and in plain text
with background lighting.
The variety of Limit level switches for side installation include:
• Type SML – stainless steel designed for contact with media with pressure
resistance up to 30 bar.
• Type NW1 – brass and stainless steel versions with NBR-butadiene with a stainless
steel or PVDF float.
• Type MW3 – microswitch variant with max 5 A switching current, electrical
connection via DIN plug 43650-A or round pug connector M12x1.
• Type NW3 – Reed switch variant in brass or stainless steel with NBR-butadiene,
stainless steel of PVDF float.
• Type RW..HK – for internal or external installation in stainless steel.
• Type MW1 – One of two micro switches, convenient for use as an advance
warning contact or for monitoring of two close levels.
Multipoint level switches for complex level monitoring with tube length
switching up to 6000 mm with a plastic version up to 5000 mm. The Multipoint
is used for distance monitoring of tanks that use up to six float stations. It offers
additional application safety with temperature elements that can be optionally
integrated in a switching tube monitor the media temperature continuously.
Effective limit level switches are supplied in a simple or double contact sensor
in proven Reed switch design. Again, these switches are available in stainless steel,
brass as well as aluminium or PVC. In continuous operation they offer temperature
resistance up to 1050°C. Optional switching functions as a NC or change-over
contact making external voltage supply unnecessary.
“The Val.co range complies with all international standards,” concluded Grobler.
“The robust devices perform in the most demanding conditions and are approved
for ATEX Exd – Exi a, EAC, and for naval use.”
The range is available from GHM Messtechnik South Africa.

For more information contact Jan Grobler, GHM Messtechnik South Africa,
+27 11 902 0158, info@ghm-sa.co.za, www.ghm-sa.co.za
 PROCESS MEASUREMENT
Yokogawa releases two new liquid
analysis products for monitoring
Sencom 4.0 additions enable flexible design and improve maintenance efficiency.
Yokogawa has announced that it has added two
new solutions to the Opre analyser family with the
development of the FLXA402 4-wire liquid analyser
and the SA11 smart adaptor. These two new liquid
analysis products will be offered as part of the
Sencom 4.0 series. It is expected that they will help
to improve the efficiency of calibration and other
maintenance tasks, and facilitate the flexible design
and operation of liquid analysis data monitoring
systems.
Liquid analysers consist of a sensor and a
transmitter with a data conversion function, and
are used to monitor items such as the quality of raw
materials and finished products, and water quality
in the wastewater treatment process. They are
utilised in a wide range of industries including power,
water supply, municipal and industrial wastewater
treatment, semiconductors, foods, pharmaceuticals,
iron and steel, pulp and paper, oil, petrochemicals
and chemicals. The two basic types of transmitters are
4-wire devices with separate cables for power supply
and output and 2-wire devices that use the same
cable for power supply and output, and Yokogawa
supplies both. Yokogawa’s 4-wire transmitters are
typically used for specific applications such as pH
measurement, and its FLXA21 and FLXA202 2-wire
transmitters can flexibly accommodate multiple
sensors of the four basic types: pH/ORP, conductivity,
inductive conductivity and dissolved oxygen.
Although the FLXA402 is a 4-wire system, it can
connect to multiple sensors, perform diagnostics, and
communicate digitally with host systems.
34 February 2019 www.instrumentation.co.za
In liquid analyser applications, there is a
need for data monitoring systems consisting
of integrated sensors and transmitters that are
capable of transmitting data directly to a control
system, recorder, indicator, or a handheld device
such as a tablet. Although such integrated
devices are able to store data that is needed for
calibration and other maintenance tasks, the
entire unit needs to be replaced when sensor
damage or fouling occurs due to exposure to
liquids. To reduce maintenance costs, Yokogawa
has developed the SA11 smart adaptor, which
also functions as a transmitter. As only the sensor
needs to be replaced, this significantly reduces
maintenance costs and eliminates waste.
Product features
The new products are the FLXA402 4-wire liquid
analyser, SA11 SENCOM smart adaptor, and pH
and ORP sensors that are dedicated for use with
the SA11. There is also a new peripheral device:
the BA11 junction box.
FLXA402 4-wire liquid analyser
Reduced cost and footprint: the instrument
can work with existing analog sensors (pH/
ORP, conductivity, inductive conductivity,
and dissolved oxygen), optical dissolved
oxygen sensors, and the SA11 Sencom smart
adaptor and its dedicated sensors. By using
it in combination with the adaptor and the
BA11 junction box, it is possible to connect up
to five sensors, reducing both system cost and
footprint. For the transfer of diagnostic data and
other device information to a host system, the the
device supports the HART and Modbus protocols.
This solution also facilitates connection to the
cloud and an IIoT environment for improved field
maintenance.
SA11 SENCOM smart adaptor
Simple but flexible system configuration: the
adaptor has functions for data conversion,
transmission, calibration, and diagnosis, and
is intended for use with dedicated sensors. It
supports the Modbus communications protocol.
Using the adaptor, it is easy to set up a system that
can perform data monitoring, calibration, setting,
and adjustment.
Improved maintenance efficiency
As the SA11 is able to store sensor calibration data
and other types of digital information, it can be
transferred to a laboratory or some other location
that is safer and has better working conditions.
This reduces the amount of maintenance work
that needs to be performed in the field and helps
to ensure that the device stays properly calibrated,
thus reducing downtime.
For more information contact Eugene Podde,
Yokogawa South Africa, +27 11 831 6300,
eugene.podde@ao.yokogawa.com,
www.yokogawa.com/za
 PROCESS MEASUREMENT

Wenglor expands optical sensor range

Wenglor’s PNG/smart generation of photoelectronic sensors is
distinguished by a combination of performance and communication.
An aligned optical axis and a balanced switching point, as well as large
switching distances and consistent integration of IO-Link, result in a
new class of sensors. In addition, the product range, including high-
performance distance sensors and reflex light barriers, is supplemented
with two new functional principles.
Wenglor’s PNG/Smart sensors are currently one of the most
comprehensive range of industry 4.0 sensors available on the market.
With three housing formats (1K, 1N and 1P) as well as seven functional
principles and a selection of three light sources (red and blue LED
light and red laser light), nearly any application for contactless object
detection can be implemented. This means that not only are automated
product changeovers for flexible production all the way down to lot sensors detect objects at distances up to 60 m. The through-beam
size 1 made possible, but predictive maintenance for increased systems sensors with 1P housing have a range of up to 2 m. These multifunction
availability and automated configuration of sensor parameters can also sensors can be used either as switching or measuring devices and, due
be implemented. to WinTec technology, they do not interfere with each other. The series is
As all sensors are equipped with IO-Link, integration into existing completed by diverse connection functions, optionally connectable via
control systems via Profinet and EtherNet/IP is available. A special NFC M8x1 or M12x1 plug, or with cable to permit all sensors to be integrated
interface allows users sensor set-up via near field communication. into any system design.
Settings can also be adjusted using a potentiometer, Teach-In, or at the
LED display. For more information contact Anastas Schnippenkotter,
Whereas the reflex sensors with background suppression and 1N ASSTech Process Electronics & Instrumentation, +27 11 708 9200,
housing format have an upper range of 1200 mm, the through-beam info@asstech.co.za, www.asstech.co.za

www.instrumentation.co.za February 2019 35

Operators step into the future
Recognising the increasingly vital role that
technology plays in business, SKF continues to
move with the Industry 4.0 tide. In line with its
‘World Class Manufacturing’ initiative, SKF has
implemented Operator 4.0, a new approach to
managing machinery and operations from the
palm of employees’ hands.
Since SKF’s launch of the ‘World Class
Manufacturing’ digitalisation model at Göteborg
plant in 2015, the company has been rolling out
new innovative digitalisation and automation
features to improve production and turnaround
times to the ultimate benefit of customers.
This automation transformation also upskills
employees and enhances their job experience
with smarter technology leading to a more
productive and safer working environment.
The introduction of Operator 4.0 relieves
operators from manual tasks and requires them
to broaden their knowledge in order to be in a
position to understand a more comprehensive
system, with multiple connections.
Smartphones enable strategic decision
making
Smartphones are a vital part of this equation as
data alerts on these devices enable operators
to interpret information and make strategic
decisions. To assist in this transition, SKF
has hired data scientists and data analysts.
These experts assist in upskilling and training
employees to equip them with the necessary
knowledge so that they are able to understand
complex systems with multiple connections to
36 February 2019 www.instrumentation.co.za
ultimately work faster, smarter and safer.
The straightforward process of data
collection to operator interpretation begins
with the operator viewing real-time data of all
machines which is conveniently displayed on
a screen mounted in the assembly island area.
The compact Multilog IMx-8 from SKF is an
online data collection instrument that offers
sophisticated, fit-for-purpose machine health
monitoring.
The most recent addition to SKF’s highly
popular IMx-16 and -32 channel machine
health monitoring platforms, the IMx-8, then
processes and interprets the data measured
by the sensors (up to 8 channels in this
case). QuickCollect is the software on the
smart device (smartphones and tablets) that
interprets the IMx-8 data in a user friendly and
comprehensible format. Through the power
of the IMx-8 and software, machinery results
detected by the sensors including temperature,
rotation speed, and vibrations, are sent directly
to the operators’ mobile phones. Operators are
able to view machine condition, when service
is required or detect problems early, thus
avoiding critical failures, costly replacements
and downtime.
In the event of an anomaly, an alert is
sent to the operator’s smartphone via the
‘MOST’ application. Developed in-house by
the Connectivity Room, this versatile
application allows the operator to move
between the assembly islands and view
the instructions at each workstation by
scanning the data matrix placed on each unit.
In addition to being privy to information
which was previously restricted, operators
are now also able to exchange information
with colleagues via an integrated chat
messaging application. This functionality
allows employees and their supervisors to be
connected at various locations.
In this digital age it is widely accepted
that new technology also means increased
risk and this too has been addressed by SKF.
The company has introduced a number of
measures to limit any potential hazards:
Segmenting the physical network into virtual
sub-networks, ordering two firewalls, and
working on the development of a system
to block viruses transferred via USB port
inputs. Furthermore, e-learning modules and
IT security workshops are conducted with
employees to generate improved awareness on
IT security and risks.
SKF employees are reaping the benefit
of cutting-edge technology through the
acquisition of new IT skills and the use of the
smartphones in the workplace. With the recent
implementation of these dynamic digital
solutions, SKF is poised to elevate employee
skills and enhance production quality and
performance for the ultimate benefit of SKF
customers.
For more information contact Samantha
Joubert, SKF South Africa, +27 11 821 3500,
samantha.joubert@skf.com, www.skf.com

Spresense platform brings
sound and vision to IoT devices
RS Components has boosted opportunities
to create smarter IoT devices by introducing
Sony Spresense, featuring Arm Cortex-M4F
performance and extensive sensing, audio, and
imaging capabilities.
The low-power platform combines the
Sony CXD5602 system-on-chip (SoC) for
wearable electronics, and the CXD5247
power-management and audio IC. Expansion
headers allow users to further extend the rich
native features by adding Arduino shields
or any of a selection of specially developed
add-on boards. These include the Bluetooth
low energy board and the Spresense-Sensor-
EVK-701 containing an accelerometer,
barometer and magnetometer. Spresense is
compatible with the Arduino development
environment (IDE) and comes with a set
of extended APIs that give developers the
additional option to use the advanced NuttX
based software development kit (SDK).
The CXD5602 SoC on the main board
contains six 156 MHz ARM Cortex-M4F cores,
ensuring generous compute performance
and low latency. Peripherals include an 8-bit
parallel camera interface, a multi-constellation
GNSS receiver, and a sensor-fusion block to
simplify movement or context sensing using
a combination of external accelerometer,
eCompass, gyroscope or pressure sensor. The
CXD5247 adds a class-D bridge-tied load (BTL)
audio amplifier, 8-channel digital microphone
and 4-channel analog microphone inputs, as
well as DC/DC converters and a low-dropout
(LDO) regulator to provide the system
power rails. Battery charging and fuel gauge
peripherals further simplify the design of self-
powered, connected smart objects.
The extension board handles interfacing
and user access to signals, featuring level-
shifting circuitry, headphone and microphone-
input headers, and an SD Card slot. Together,
IT IN MANUFACTURING
the high-performing audio, video, sensing,
and positioning capabilities of Spresense,
made accessible by this two-board platform,
enable users to create even more advanced IoT
devices and smart objects.
With its multicore compute engine and
built-in GPS, the platform is ideal for next-
generation drones. Support for high-resolution
audio recording and playback, and the full
digital amplifier, create a perfect platform for
new and more powerful smart speakers. On
the other hand, the built-in camera interface
can support numerous opportunities for smart
cameras and networked vision applications
such as security surveillance or remote time-
lapse cameras.
For more information contact
RS Components SA, +27 11 691 9300,
sales.za@rs-components.com,
www.rsonline.co.za
www.instrumentation.co.za February 2019 37
Towards the Smart Factory
With much of the reported paradigm of
Industry 4.0 resting on self-configuration of
machinery and production lines, Omron’s
Victor Marquess looks at what can already be
achieved to get on the path to an Industry 4.0
future and the promise of the Smart Factory.
Mass production is giving way to shorter
batch runs, just-in-time production and
increasing levels of customisation, which
demand the flexibility of the Smart Factory.
Not only does this require more intelligent and
sophisticated production processes, but also the
ability to reconfigure everything from individual
machines to complete production lines, without
incurring delays between batches. And, as batch
sizes become smaller, so the need for shorter
changeover times becomes more acute.
Production line changeovers have moved
from mechanical readjustments to a button
push on an HMI, dramatically reducing
reconfiguration times. But as the requirement
for more frequent changeovers has grown, so
has a need for greater intelligence in the self-
configuration process. There is now increasing
pressure on machine builders to deliver
machines that are ‘Smart Factory ready’, and
which can configure themselves quickly and
with less operator interaction.
With the advanced integrated functionality
of components such as PLCs, drives, servos,
sensors, HMIs and robotics, plants already
have the means to implement a Smart Factory
38 February 2019 www.instrumentation.co.za
production environment as everything
required for self-configuration is already
available.
Software is the key
For machine builders, programming self-
configuration capabilities within the machine
cannot be an afterthought. “Addressing
self-configuration late in the machine design
process always results in a less capable system,
compromising competitive advantage and
increasing development costs,” explains Marques.
Traditionally, programming this added level
of functionality into the machine has been
a challenging and time-consuming process,
adding cost. And if there is little commonality
from one machine design to the next, the
economics of increased programming time
might not add up. However, help is at hand.
Omron has focused on making the software
side of development quicker and easier for those
machine builders and end-users committed
to the Industry 4.0 paradigm. The company
provides a complete library of pre-written,
pre-configured and pre-tested function blocks
that dramatically speed up the programming of
advanced functions at every stage in the machine
development – not just at the end of the project.
Modular and reusable, the function blocks can
be dropped into the design as needed, and then
simply embellished to meet the needs of the
specific Smart Factory application.
There are currently more than 40 function
blocks, to choose from, with more being
written, tested and added all the time.
Examples include motion control, path control,
tension control, temperature control, servo
settings, sensor set-up, vibration suppression
and device operation.
While today’s requirement may be for
shorter batch runs as a minimum requirement,
the mass customisation envisaged by Industry
4.0 might be the base requirement in just a
few years’ time. Indeed, many industries are
already looking at so called ‘batch size one’
requirements, where every product coming off
the line might be subtly different to meet the
needs of individual customers.
“Omron’s function blocks mean that
even the most sophisticated machine
applications no longer need to be last
minute considerations as an afterthought
value add proposition,” concludes Marques.
“Machine builders can begin to add advanced
functionality such as self-configuration as
part of the standard machine development
process, helping to deliver all the competitive
advantage that the Smart Factory concept
promises.”
For more information contact Omron
Electronics, +27 11 579 2600,
info.sa@eu.omron.com,
www.industrial.omron.co.za

Unobtrusive approach to digitalisation
As Industry 4.0 continues to unfold, increasing
numbers of manufacturers, big and small, are
seeking the best opportunities to increase the
automation of their industrial processes and
improve productivity. However, how many fully
understand the various aspects of digitalisation
and its practicalities? Perhaps more pertinently,
what can be achieved right now, and at what
pace should it be implemented?
The adoption of digital systems and factory
connectivity is clearly of significant competitive
advantage. However, most are still getting to
grips with the results that can be realised, and
the associated benefits they can derive.
Different needs
Looking at the current market, there appear
to be two categories of manufacturer looking
to digitise their operations: those that want
to restructure the whole company to make
the most of the latest digital technologies
and have a fully automatic factory; and those
seeking a more ‘discreet’ approach, namely the
gradual equipping of components with digital
connectivity and making them visible in the
cloud via the IIoT.
The latter does not demand a complete
revolution of the company, but rather, a strategy
that helps manufacturers to see initial results
such as the registration of data coming from the
machines, as well as the alarm settings and data
analysis of the production cycle, for example.
These are the first steps that allow a company to
gear-up and develop internal capabilities on the
path to full automation.
One of the initial hurdles faced by many
manufacturers is that their machines, systems
and equipment communicate in different
protocols. Here, the goal of IIoT facilitators
is to bring together the different systems in
one shared platform – at Parker Hannifin this
platform is called Voice of the Machine. In fact,
it will likely not be long before a centralised
database exists for all products, indispensable
for a tomorrow when thousands, if not millions,
of components will be interconnected. In
such a concept, a unique code will identify
all the features of a product, which will have
both a physical and digital appearance (a digital
twin).
As a step towards this future, the IO-Link
communication protocol has been introduced
on the whole range of Parker equipment.
IO-Link allows users to enlarge the number of
devices connected and integrate components
in the system.
Infrastructure platform
As part of a macro strategy, all products enabled
by the IIoT will be connected in an infrastructure
platform such as Voice of the Machine, which
also includes software, a platform in the cloud
and a dashboard-style front end. Through this
architecture, every machine, component or
system can communicate securely with others
thanks to a common structure of standard
protocols and shared principles.
A typical component helping to facilitate
digital manufacturing environments is the
smart sensor, which, using a wireless or
Bluetooth connection, is able to record pressure,
temperature and humidity values. Such sensors
are easily installed and eliminate the issues
associated with hard wiring. They can be
visualised on a smartphone app, allowing users
to view the data collected, along with initial
analysis routines.
More and more industrial components
are being equipped with a digital interface.
Importantly, solutions of this type are not just for
new-build machines; it is possible to place smart
sensors at critical points in existing systems, and
equip them with a gateway for connection to the
cloud. Specially devised retrofit kits are available
complete with all the necessary sensors to make
this passage. Once installed, the maintainer
receives any alarm events on their smartphone,
without having to go looking for them on site or
on a remote display.
“The goal of IIoT
facilitators is to bring
together the different
systems in one shared
platform.”
Predictive maintenance
Of course, predictive maintenance is the goal
of many modern manufacturing businesses:
a strategy that can be aided tremendously by
digitalisation. Using the data collected from
smart sensors, it is possible for advanced
algorithms or accurate data analysis to predict
when a specific component or system will need
replacement or maintenance. Moreover, some
developers of IIoT technology can now provide
specially developed functional modules that
present a digital representation of objects and,
using special algorithms, make predictions that
IT IN MANUFACTURING
lead to plant optimisation based on the data
collected.
Take a hydraulic system, for example, where
one of the most common faults is contaminated
oil. With this in mind, a first approach towards
efficient predictive maintenance must be a
real knowledge of the oil conditions within
the circuit. This knowledge is facilitated by
sensors and equipment that allow complete
monitoring of oil health. The point here is that
the company must also change its approach as
the importance of having proper fluid health
monitoring is often underestimated, which if
ignored, can cause enormous damage. Thus, a
complete management service for fluid health
is required.
A complete solution involves a wide range of
sensors and instruments that permit a detailed
analysis of fluids for each type of contaminant
and precise monitoring conditions: periodic
or continuous. Following diagnostics, the
contaminants can then be removed from
hydraulic systems to extend the useful life of
the fluid, and prevent unwanted and expensive
machine stoppages.
Measured pace
From observations to date, while there is a
deep interest in the IIoT among manufacturers,
the adoption of facilitating technologies will
almost certainly be at a measured pace in many
instances. Even many large companies are still
not equipped with the staff and appropriate
software required for the correct analysis of the
large amount of data they will be collecting.
Data analysis is a complex job. Small
businesses need a vertical solution: component,
gateway, cloud, software and a complete
management service. Bigger companies, on the
other hand, which already have their platform in
place, are more interested in digital components
and functional modules that fit as ready-made
plug-ins, generating not only data, but analysis
of the results.
Taking a holistic view, there is no question
of whether the digital revolution will happen or
not; it is only a question of when and at what
rate. In the meantime, manufacturers would
do well to make themselves protagonists of a
strategy that will aid the permeation of digital
technologies as part of a disubtle approach.
For more information contact
Lisa de Beer, Parker Hannifin SA,
+27 11 961 0700, lisa.debeer@parker.com,
www.parker.com/za
www.instrumentation.co.za February 2019 39
Enhanced intelligence at the edge
A new computing model that helps create
autonomous edge nodes is changing the IIoT
landscape. Edge nodes are data-aggregation
points in an IIoT system, where the physical
world of sensors and actuators interacts with
computational resources such as IIoT gateway
computers. This new computing model is
based on edge nodes that are enhanced
with local storage and computing power,
in addition to machine-learning algorithms
that enable them to process data locally and
make quick decisions. An intelligent edge
node enables faster decisions according to
local identity management and access control
policies, secures data close to its source, and
reduces communication costs.
Edge intelligence is edge computing
fortified with machine or self-learning
algorithms, advanced networking capabilities,
and end-to-end security. This article discusses
four key elements of a good edge intelligence
solution.
1. Localised data processing
The troves of data collected at the edge of
a network can quickly lose their relevance.
Hence, the data should be processed and
useful insights derived from it at the earliest
opportunity. Mission critical systems, such
as healthcare and factory monitoring,
require quality data measurements and
instant decisions. In addition to being time
consuming, sending data from the edge to
40 February 2019 www.instrumentation.co.za
the cloud can lead to data corruption and
processed data without the required context.
For these reasons, the edge node should
be equipped with the ability to process data
locally and only key information should be
sent to the cloud to develop data models.
Edge nodes with local storage and processing
capabilities keep the data closer to the source.
2. Real-time decision making at the edge
Edge intelligence enables real-time decision
making at the edge nodes. Decision latency
can be drastically reduced by enabling edge
node analytics. Machine learning or self-
learning algorithms can be developed locally
or in the cloud and deployed at the edge to
make the edge nodes autonomous, enabling
quick decision making.
3. Robust edge-to-node communication
Data integrity is key in the edge-computing
model because decisions are made at the
edge node level. Data that is sensed and
measured at these devices is of little use if
the communication between the devices
and the edge node is not consistent. No
data loss or data corruption can be tolerated
as the edge node is now responsible for
making key process-related decisions. Other
communication aspects to consider are range,
bandwidth, device-to-device communication,
the communication protocols to support, and
how to power edge devices. A good edge
network is one that is optimised for wireless
sensor communication.
4. Secure edge
The lifecycle of an IIoT system is often longer
than a traditional computing system as
many edge devices remain in operation even
decades after they were deployed. While
servers and PCs are complex enough to allow
for security provisions, IIoT nodes are usually
low in power consumption and processing
power. Edge-intelligence solutions equip the
edge node with local storage and processing
power and a varied set of software and
hardware options help secure the edge devices
and nodes. Some of the methods used to
secure the edge nodes include:
• Secure edge platform with end-to-end security.
• Intrusion prevention systems (IPS).
• External hardware security.
• Secure boot capability.
Since edge nodes are the gateways to the
physical world, when an edge device or node
is compromised it is not just data that is at risk.
Cyber attackers can now potentially access
unsecure edge nodes and devices to interfere
with industrial processes or shut down
equipment resulting in financial loss and even
life-threatening situations.
For more information contact RJ Connect,
+27 11 781 0777, info@rjconnect.co.za,
www.rjconnect.co.za
Digital Enterprise offering with
­future technologies for Industry 4.0
By expanding its Digital Enterprise portfolio
and integrating future technologies, Siemens
is driving forward the digital transformation of
the discrete and process industries. “An ever-
increasing number of industrial enterprises,
particularly SMEs, are well on the way towards
Industry 4.0, and are already improving their
competitive standing with digital solutions,”
explained Klaus Helmrich, member of the
management board of Siemens. “This applies
to all sectors of industry, with rapidly changing
market demands in which products have to
be manufactured ever more quickly, flexibly
and in diminishing quantities. With the further
integration of technologies such as artificial
intelligence (AI) and edge computing into our
portfolio, we’re paving the way for the future
of industry.”
Industrial Edge and AI
Industrial Edge is a concept devised by
Siemens for the discrete and process industries
to enable data processing on the machine
level as the optimal complement to cloud
computing with the open IoT operating system
MindSphere. Users benefit from the integration
and flexibility the system allows for the analysis
of data, either on the field level or in the cloud,
depending on requirements.
Siemens is providing further support
to its customers undertaking their digital
transformation with the integration of AI
42 February 2019 www.instrumentation.co.za
technologies. Initial AI applications have already
been successfully implemented in Siemens’
own facilities: at the Siemens Electronics
Factory in Amberg, for instance. Here, Edge
devices working with AI are used to implement
predictive maintenance measures, reducing
unscheduled machine downtimes due to
motor bearing damage on printed circuit board
milling machines by 100 percent. Siemens is
additionally launching a new module with
an integrated AI-enabled chip for the Simatic
S7-1500 controller. This enables functions such
as quality controls and robot-based handling
processes to be optimised through the use of
machine learning algorithms.
Innovations include the Sinamics G120X
converter series, which has been optimised for
pump and fan applications in the infrastructure
industry. Using Sinamics Connect 300, these
devices can also be linked to MindSphere,
enabling users to optimise their processes and
maintenance strategies by analysing operating
data gathered from converters, drive trains and
machines.
Sidrive IQ is a digital platform offered by
Siemens for the analysis and utilisation of data
from drive systems. On the basis of networked
Siemens drive systems, this cloud-based
application is now also available for motors and
converters in the medium and high voltage
ranges.
At SPS Drives 2018, Siemens also
showcased three new application packages
for MindSphere: Connect & Monitor, Analyse
& Predict, Digitalise & Transform, all including
comprehensive advisory services. These
new packages will allow even faster, simpler
implementation of IoT projects by users, for
instance by speeding up the connection,
analysis and optimisation of assets and by
predicting and preventing unscheduled
plant downtimes. They will also simplify the
development of new services and business
models. The growing ecosystem surrounding
MindSphere is set to additionally benefit
users by enabling a high level of flexibility
in the choice of infrastructure (Amazon Web
Services, Microsoft Azure, Alibaba Cloud). By
acquiring Mendix and its low-code platform,
Siemens is supporting in particular small and
medium-sized enterprises to develop their own
applications. The number of members affiliated
to the MindSphere World user organisation
continues to grow, currently numbering 37 in
Germany and 18 in Italy.
Helmrich explained the significance of
cooperation in the Industry 4.0 age using
examples such as the recent Siemens affiliation
with Aruba in the field of communication
networks. Siemens has joined forces with
Aruba, a Hewlett Packard Enterprise, in a
strategic partnership for integrated networks.
On the basis of their complementary product
portfolios, they will be providing support to
 IT IN MANUFACTURING

customers in the implementation of integrated
communication networks, all the way from
factory floors to corporate offices.
Another example cited by Helmrich was the
company’s extended cooperation with Bentley
Systems. Both companies recently announced
their joint development of PlantSight Cloud
Services, based on their highly complementary
software portfolios. These services will afford
users anytime access to 1D/2D/3D data using
a simple web portal – making a continuously
updated digital twin of a plant available to all
users. Given the long service life of process
plants and on-going investment projects, this
offers a decisive benefit particularly to plant
operators.
As the digital transformation progresses,
cyber security is becoming a major success
factor for an increasing number of companies.
Here, Siemens offers a holistic industrial
security concept based on products and
services. As framework conditions and security
requirements can vary, specifically tailored
solutions are required for different sectors
of industry – from discrete manufacturing
through to the process industries. Siemens
is the first company in the world to achieve
TÜV SÜD certification for the secure system
integration of process automation and drive
solutions in compliance with the international
IEC 62443-2-4 standard.
The Digital Industry Services offered by
Siemens are designed to support customers as
they work towards customised implementation
of the Digital Enterprise – from consulting
through implementation to data analytics.
For more information contact Jennifer
Naidoo, Siemens Digital Factory and Process
Industries and Drives, +27 11 652 2795,
jennifer.naidoo@siemens.com,
www.siemens.co.za

Simple connection of converters

supports cloud-based applications
The new Sinamics Connect 300 from Siemens
provides a simple plug-and-play solution for
integrating converters of the Sinamics family
into the IT world. The new solution is suitable
for low-voltage converters and supports cloud-
based digitalisation solutions.
MindSphere applications such as Analyze
MyDrives can now be used directly via Sinamics
Connect 300. Sinamics Connect 300 is an IoT
gateway with its own dedicated LAN connection.
The converter is connected directly to the
Sinamics Connect 300 terminal block. Parameters,
operating data and statuses are being transmitted
over universal serial interface protocol and can
be retrieved at any time. No modifications are
necessary to the hardware or firmware of drives
used with Sinamics Connect 300, nor do PLC
programs need to be adjusted. Commissioning
takes place conveniently and simply using a
web server user interface. Sinamics Connect 300
does not bring about any changes to the data
and signal flow of the machine automation, nor
does it place any additional load on the fieldbus
of the machine or plant. This makes the use of version. Analyze MyDrives allows operators intervals is no longer required, enhancing
Sinamics Connect 300 completely independent to monitor the drive components of their machine capacity utilisation and productivity
of the automation and enables rapid, trouble-free machines. The app collates and evaluates all while reducing maintenance intervals and
and low-cost commissioning. The simultaneous the operating data, and can be used to analyse downtimes. The analysis of operating data
connection of up to eight drives opens up and visualise any parameters, or to define the also enables predictive maintenance and so
outstanding economies of scale, and the Sinamics threshold values and work area. By continuously reduces the risk of unscheduled costs, allowing
Connect 300 is also highly suited for machine users monitoring power consumption, torque and all optimisation potential to be channelled into
looking to directly upgrade heterogeneous legacy frequency, it enables the determination of energy-saving measures.
machine fleets in brown field projects. actual maintenance requirements. As a result,
machine operators are informed about any For more information contact Jennifer
Analyze MyDrives now also available for critical operating statuses within the drive train, Naidoo, Siemens Digital Factory and Process
the latest MindSphere version and machine builders are able to offer servicing Industries and Drives, +27 11 652 2795,
The MindSphere app Analyze MyDrives is being tailored to actual needs. Regular machine jennifer.naidoo@siemens.com,
prepared for use with the latest MindSphere maintenance performed generally at predefined www.siemens.co.za

www.instrumentation.co.za February 2019 43

 ENCLOSURES, CABLING & ACCESSORIES
Enclosure series for explosion
protection in process automation
For many years, users have been waiting for a
new, universal enclosure system in the field of
electrical explosion protection. Having invested
in this area, Pepperl+Fuchs has developed the
GRP enclosure series with its wide variety of
relevant features. The design concept is the
result of extensive experience in explosion
protection and brings together a high degree
of flexibility, for wide range of applications with
little planning required.
The sophisticated mounting grid
demonstrates the tremendous flexibility of the
system and its high level of practical relevance.
With this design, terminals and control
elements can be planned and implemented
according to customer-specific requirements
and any DIN rails can be easily mounted using
self-tapping screws, without the need for
time-consuming engineering. An innovative
spacer system enables the use of different
components at different heights within an
enclosure. In addition, this system increases
flexibility during the planning process and
allows significantly more functions to be
combined in a single box.
Flexible planning, efficient handling
The boxes themselves are offered in a range
of enclosure sizes and depths, which, when
44 February 2019 www.instrumentation.co.za
combined with the new spacers, guarantees
virtually unlimited flexibility in the planning
process and the optimum use of space.
Perhaps an unusually high number of
cable glands has been specified? No problem,
this is simple to implement with minimum
effort. Is an extra row of terminals required
in addition to the operating elements?
Just like that, the required result can be
achieved quickly and efficiently without
mounting plates. And likewise, when planning
straightforward terminal boxes the new
flexibility offers far more possibilities for
customised tailoring. If the customer wants
the DIN rail to be mounted slightly higher
because cables need to run below it, this can
be achieved quickly and efficiently with the
new enclosure series.
However, what truly makes the GRP
enclosure is its many useful and innovative
features. The sealing concept for IP66 impresses
not just with a captive formed-in-place silicone
foam seal, but the concept also features a new
protective upstand that prevents mechanical
damage to the sealing edge and is completely
unique on the market. Using this sealing
concept, it is even possible to stack the boxes
with the lid open with the sealing edge
well protected during installation or when
adding extensions. A further innovation with
significant benefits for process automation,
the new GR box can be used at a temperature
of -60°C. The customer therefore has a
low-cost alternative to stainless steel, in many
cases even under difficult environmental
conditions.
The new solution also offers significantly
reduced effort required for installation. Due
to the intelligent design, it now takes just
one person to fit even larger and heavier
boxes. First, two screws are drilled into the
wall and used to hold the enclosure in place.
The remaining screws are then inserted, and
everything is tightened at the end. This process
saves time, therefore considerably reducing
costs during installation and maintenance.
Another feature the service team may find
practical are the especially sturdy hinges that
allow easy opening of the lid. The hinges
are fastened with screws that do not pierce
through the enclosure. This approach is taken
for nameplates too. And one more thought
put in for practitioners: leverage points for
screwdrivers enable easy opening of the lid,
thus saving time and ensuring easy handling
during maintenance.
Quick availability
For plant engineers and machine builders,
what counts in an enclosure solution is not
only that it is tailored to their needs, but how
quickly the product is available to them. For
this reason, Pepperl+Fuchs supplies enclosures
that are precisely tailored to user requirements
almost as quickly as if the products were
available off the shelf.
Terminal boxes and control stations are
the first products available with the new
GR-enclosure series. Later, the enclosures will
become available for remote I/O and fieldbus
applications. In addition, an engineering
team, specialists in electrical installation
and hazardous area protection, stand by to
plan tailor-made solutions. During planning,
engineering and production, the priority is
always the requirements of the enclosure and
the shortest possible delivery time.
For more information contact Pepperl+Fuchs,
+27 87 985 0797, info@za.pepperl-fuchs.com,
www.pepperl-fuchs.co.za

Rittal’s new industry-
first enclosure system
Following the official launch of Rittal’s
new VX25 large enclosure system at last
year’s Hanover Trade Fair, Rittal South
Africa unveiled this evolution during a
customer day which took place last year.
After five years of development work,
the VX25 is an enclosure system that
has been fully developed to meet the
requirements for increased productivity
in control and switchgear manufacturing,
and along the Industry 4.0 value chains.
With the ‘System Perfection’ slogan, Rittal
offers a major innovative leap, made
possible through depth of experience
and intensive customer dialogue.
The VX25 offers high quality, reduced
complexity and easy assembly. The
uptake has been exceptional and the
range has gone on to include a Blue e+
version, which offers revolutionary energy
efficiency thanks to hybrid technology.
Observe, listen and learn
Intensive dialogue with Rittal customers
was crucial in developing the new large
enclosure system. During a large-scale,
scientifically-based usability study,
researchers used words, images and
moving film to document the everyday
working life of control and switchgear
manufacturers, covering ten companies
in Germany, eight in the US and six in
China, including small, medium-sized
and large companies. As a result, 150
systematically recorded and specific
ENCLOSURES, CABLING & ACCESSORIES
RS launches
rugged Molex
connectors
RS Components has introduced the Molex Squba range of
1,80 mm sealed wire-to-wire connectors, designed to fit into
small spaces while offering IP67 protection against liquid, dust
and dirt. Squba supports currents up to 6 A carried over No. 24
to No. 22 AWG wire, delivering more power over such a small
wire gauge than other connector systems on the market.
System integrators in the industrial and transport
sectors are expected to incorporate ever greater
functionality into their designs, making it difficult to
squeeze all the required components into the available
space. Many applications also experience wet or dusty
conditions that can cause unsealed connectors to fail.
With a terminal pitch of just 1,8 mm combined with
IP67 protection, the Squba connector system ensures a
reliable connection even in space-constrained, harsh-
environment applications such as outdoor lighting,
HVAC equipment, security systems, robotics, industrial
requirements for a new enclosure
motors and machines, food processing equipment, liquid
emerged, providing developers and
dispensers, all-terrain vehicles (ATVs), and lighting and
product managers with a robust guide
under-dash wiring for boats and other marine vessels.
for the actual development work.
The Molex design features a protected, low-profile
positive latch that stops wires getting caught during
Pure customer benefits and a high
assembly while keeping the overall connector package
degree of innovation
size small. Seal caps with protective guide channels align
The development culminated in the new
terminals to provide additional security against seal
VX25 large enclosure system where the
puncture during assembly, and also protect against seal
name stands for the versatility of options,
damage during handling, shipping, insertion and operation.
the fulfilment of customer requirements
The wire-to-wire connector system comprises plug
and for perfect symmetry through a
and receptacle housings and crimp terminals that can be
consistent 25 mm pitch pattern. The
assembled in 2 to 10-circuit configurations, including void
VX25 matches the way the control and
options for 3, 5, 7 and 9-circuit requirements. Clean-body
switchgear manufacturer thinks and works
terminals with wrap-around insulation crimps are used to
– both in functionality and processes.
help prevent seal punctures. Each female terminal has two
The heart of the innovation is the
contact points and two serrations in the conductor crimp
newly-developed frame section. It
area to enhance electrical and mechanical performance. A
determines the installation space, the
primary lock provides 30 N terminal retention force.
efficiency in engineering and assembly,
the expansion options, the stability and
thus the reliability and flexibility in the
customer’s workshop. With the new
enclosure system, it is possible to maintain
all the important and established product
features of the existing TS 8 range and
to expand them significantly with a
multitude of new functions and customer
benefits. More than 25 registered patent
and trademark applications demonstrate
the high level of innovation in the VX25.
For more information contact Rittal For more information contact RS Components SA,
South Africa, +27 11 609 8294, +27 11 691 9300, sales.za@rs-components.com,
info@rittal.co.za, www.rittal.co.za www.rsonline.co.za
www.instrumentation.co.za February 2019 45
 ELECTRICAL POWER & EFFICIENCY
Compact soft starters for control
of three-phase motors
Soft starters limit the inrush current, improving
overall stability of the power supply and
reducing transient voltage drops, which may
affect other loads in a network. They are ideal
for applications demanding high-performance
in terms of control and protection during
motor start-up and operation.
Soft starters can avoid pressure surges and
prevent water hammer in pump applications.
Conveyor belt systems can be started
smoothly, avoiding jerks and other stresses on
drive components. Fans, or other systems with
belt drives, can be started slowly to avoid belt
slipping.
“The new ADXL series from Lovato,
distributed by ElectroMechanica (EM),
comprises modern, state-of-the-art, compact
soft starters for three-phase motors from 7.5
to 160 kW, in four frame sizes,” explains EM
product manager, Jaap Grobler. “They allow
control of starting, stopping, monitoring, and
protection, with integrated functionality for an
46 February 2019 www.instrumentation.co.za
extremely efficient starting solution. A bypass
facility is provided on all sizes, which operates
when the start-up function has completed,
thus reducing power losses and saving energy.”
Wide operating voltage in a
compact design
A wide operational voltage range of 208 to
600 V AC, a compact design and advanced
functionality make the ADXL series a
highly efficient solution for most industrial
applications. Two-phase control during motor
starting and stopping, combined with torque
control during operation, provides optimised
ramping characteristics.
This ensures smooth start and stop
functionality, significantly increasing lifespan
of connected motors and power transmission
devices. Hence the ADXL series is an excellent
choice for pumping applications where water
hammer is normally a problem. Kick-start
functionality delivers high torque only during
the initial starting period, permitting motors to
be started when initial torque is insufficient to
overcome friction.
The ADXL series is equipped with built-in
electronic overload protection, protecting
the motor from overheating. No additional
overload device is required, saving space and
installation time. A backlit LCD icon language-
neutral display is incorporated on the fascia for
quick and easy configuration and visualisation
of all measurements and status parameters.
Alarms and text can be displayed in
any of six languages. Icons indicate default
application set-up in use, while graphic bars
indicate the motor and internal thyristor
temperatures, and an alphanumeric display
shows texts and measurements as well as the
current status of the starter.
Input and output functions are pre-
configured to the most common settings,
but can be easily overridden to adapt the soft
starter to specific application needs. The series
incorporates two counters, dedicated to the
number of start-ups and motor operating
hours, to set possible thresholds for potential
maintenance purposes.
Set-up is a easy, as the soft starters are
supplied pre-configured for most common
applications such as centrifugal pumps,
fire-fighting pumps, conveyer belts, fans,
mixers, and general purpose. Selecting the
required application automatically updates the
parameter programming.
Programming can be done via the front four
button controls, together with the Icon display,
or via a front-mounted optical port that can be
configured to connect to a computer via USB
or WiFi using optional accessories, or simply
via NFC (near field communication), using
compatible smartphone or tablets, even with
the starter turned off.
All starters are equipped to receive a
dedicated RS-485 Modbus communication
card, permitting constant monitoring of all
starter measurements, or to connect to an
optional remote keypad with display to view
the measurements, or to perform the set-up on
the front of the enclosure.
For more information contact Karen Zotter,
ElectroMechanica, +27 11 249 5000,
karenz@em.co.za, www.em.co.za

Forward-thinking municipality uses
pumps to generate electricity
A technical team serving the requirements of
the Drakenstein municipality in the Western
Cape has designed one of the country’s largest
pump and turbine stations to be used for water
reticulation to the nearby town of Paarl during
dry periods, and to generate electricity for the
city during the remainder of the year.
The city’s engineer for water operations,
Hein Henning, says they were faced with the
dilemma of having to pump water to their
neighbour for just one month a year. For the
rest of the time the pump station would be
dormant and need expensive maintenance due
to possible corrosion, perishing, lubrication
and bearing damage to the idle infrastructure.
Instead, the progressive municipality chose
to innovate and generate an income while
simultaneously reducing the requirement for
maintenance by effectively allowing the pumps
to run backwards against the pressure of water
from its elevated Lreservoir and generate
electricity for the region’s electrical grid.
Power Generation
The commissioning of the pump and turbine
(PaT) station effectively brings online one
of the largest such project of its kind in
South Africa, able to generate 57 kW, which
is enough to power the entire region’s
water infrastructure of treatment plants,
pumphouses, offices and other infrastructure.
“The water comes from the City of Cape
Town Wemmershoek Dam and is gravity-fed to
our city regions via the main reservoir,” explains
Henning. “For one month of the year, the
pumps need to be switched on to pump 400
litres per second upstream to Paarl, where after
they would usually be switched off.
“However, the higher elevation of the
reservoir allows us to rotate the pumps
backwards to act as small turbines for the rest
of the year which is able to generate electricity
at 80% efficiency. Unlike turbines however,
the pumps are standard stock items from the
supplier, KSB Pumps and Valves, and do not
require specialised support and servicing.
What’s more, the pumps are durable enough
to allow us to design the infrastructure with a
40-year lifespan.”
Technology integration
Before commissioning the project, the
municipality had spelled out its requirement to
replace its existing 96 litre-per-second pump
station with a new one and discussed the
ability to generate electricity in the off season
with consulting engineers, Aurecon. Having
designed and planned a solution, the main
contract was awarded to Hidro-Tech Systems
for mechanical and electrical work.
Brian Cooper of Hidro-Tech says that despite
the relative simplicity of the mechanical design,
it required complex integration of controls to
deal with the hydraulic force and convert the
electricity generated into a useable form. This
required pump speeds to be controlled via a
variable speed drive to prevent over speed, as
well as convert the wave produced to a pure
50 Hz sinusoid compatible with the city’s
power grid.
“The system is designed with full PLC
control that can be managed on site HMI, or
ELECTRICAL POWER & EFFICIENCY
accessed remotely to give users control and
monitoring of the site wherever and whenever
required,” he elaborates. “The industrial
network automates the entire system including
control and monitoring of the pumps,
valves, level indicators, flowmeters and other
equipment critical to the systems efficient
operation.
“In addition to providing seamless control
of the system, it also ensures redundancy in all
operating conditions and provides emergency
measures in the event of failures, or parameter
changes as required to rectify any operating
problems incurred.
Project results
Following the commissioning of the pump
station and turbines the system has begun
operating at full capacity and the Drakenstein
municipality has started reaping the benefits
of its forward-thinking water management
strategy.
“We are pleased with the outcome and
commend everybody involved in the project
for their innovation and dedication to building
a system that can be used as a blueprint by
other municipalities around the country,”
concludes Henning. “It has been a brilliant
project with many challenges and plenty of
innovation. We look forward to tackling similar
projects in the future.”
For more information contact Annett Kriel,
KSB Pumps and Valves South Africa,
+27 11 876 5600, annett.kriel@ksb.com,
www.ksb.com
www.instrumentation.co.za February 2019 47
 ELECTRICAL POWER & EFFICIENCY
How to optimise power quality in
critical applications
As global energy consumption continues to
rise, energy is becoming more decentralised
and decarbonised. While demand is estimated
to increase by 70% through 2040, 50% of new
energy generation capacity will be represented
by solar and storage by 2030.
In answer to these trends, the way
we manage energy is changing. Power
distribution is becoming more digitised, aiding
the transformation to smart buildings and
factories. With more complex and sensitive
loads and generation to manage, regulations
and standards to comply with, and hidden
opportunities to leverage, intelligent power
systems are giving facility teams simpler ways
of understanding their electrical systems that
enable fast and effective decisions.
“The IIoT has now been fully extended to
the facility infrastructure, with smarter devices
being connected to software systems and the
cloud,” says Preshlen Chetty, offer manager
power solutions at Schneider Electric. “It is
estimated that the total number of connected
devices across all categories of smart buildings
will reach over 10 billion by 2021. Similarly,
power distribution has evolved to include
48 February 2019 www.instrumentation.co.za
a network of connected products with
embedded intelligence.”
Digital tools enable faster response
It has become increasingly challenging to
optimise power reliability, energy costs,
and operational efficiency in critical power
environments such as hospitals, data centres,
airports, and manufacturing facilities.
Addressing these challenges requires new
digital tools designed specifically to enable
faster response to opportunities and risks
related to power system reliability and
operations.
To keep up with this changing landscape,
new kinds of power management tools are
emerging that deliver connected intelligence
to reveal every risk and opportunity, the
highest possible metering accuracy for greater
precision and certainty, modular, customisable
platforms to adapt to changing needs and
cybersecurity best practices to protect the
power network.
“Embedded metering in smart equipment
is cost-effective and convenient for basic
monitoring applications such as energy usage,”
says Chetty. “For more advanced applications,
such as power quality monitoring and power
event analysis advanced power quality meters
are required.”
Smart equipment and power meters,
designed to share their information with the
other layers of the architecture such as edge
control and cloud-hosted analytics, not only
help to optimise power quality and reliability
in critical power environments, but they also
deliver the facility-wide energy consumption
data needed to find energy waste, improve
energy efficiency, and lower electricity costs.
“When choosing an energy meter, it is
important that the product’s accuracy has
been third-party verified and complies with
all aspects of the accuracy standard. It should
also offer on-board data logging and high-
resolution metering,” adds Chetty. “The meter
and system-level software must also provide a
billing module configured to match the utility
tariff schedule.
“Some of the newest advanced meters
and power management systems also offer
modular designs that enable adaptation to
changing needs. They have also become
more scalable, partially due to the trend in
IoT-enabled communications. But advances
in network configuration tools and database
management are making it simpler to add
devices and connections when and where
required.”
Schneider Electric offers an advanced,
accurate power quality meter, the PowerLogic
ION9000 series. This newest addition to
the EcoStruxure Power portfolio provides
a complete power quality meter for critical
power applications.
“The power quality meter of the future, the
ION9000 provides future-proof adaptability, a
precision platform, it is highly customisable,
sets a new industry benchmark for accuracy,
and has a complete power quality analysis
tool right out of the box so it can immediately
identify and help solve power system events,”
concludes Chetty.
For more information contact
Prisca Mashanda, Schneider Electric SA,
+27 11 254 6400,
prisca.mashanda@schneider-electric.com,
www.schneider-electric.co.za
 ELECTRICAL POWER & EFFICIENCY

Compact DIN rail power supply

TDK Corporation has announced the
introduction of the TDK-Lambda brand
DRF960-24-1 DIN rail mount AC-DC power
supply, rated at 24 V 40 A (960 W) with a 60 A
(1440 W) peak for 4 seconds. The product has
a narrow (110 mm) width, freeing additional
space for other DIN rail assemblies. With an
efficiency of 95%, significantly less internal
heat is generated with operating field life
calculated at greater than 10 years at 75%
load, 40°C ambient, and 230 VAC input. This
energy efficient power supply is suitable for a
wide range of industrial applications including
factory automation, process control and test
and measurement equipment.
The 24 V output is adjustable from 24-28 V,
using the front panel potentiometer or an The supply is housed in a robust metal 55032-B radiated and conducted emissions,
external 5-6 V DC source to compensate enclosure and can operate from a wide 180- and complies with the EN 61000-4 immunity
for blocking diodes or FETs in redundant 264 V AC input. It is rated for operation in -25 to standards.
configurations. Also provided as standard 70°C ambient temperatures, derating linearly
is a DC OK relay contact and remote on/off above 60°C to 50% load at 70°C. For more information contact
functionality. Up to five units can be connected The unit is safety certified to IEC/EN/UL/CSA Accutronics, +27 11 782 8728,
together in parallel when set in droop mode 60950-1, UL 508 and CE marked for the Low info@accutronics.co.za,
current share. Voltage, EMC and RoHS Directives. It meets EN www.accutronics.co.za

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reduced total cost of ownership to the agricultural sector. Tel: 0861 009378 www.zestweg.com
 ELECTRICAL POWER & EFFICIENCY
Power supply protects against
hour-long power failures
Siemens has upgraded its Sitop PSU8600
power supply system with the addition of
new supplementary modules to transform it
into an uninterruptible DC power supply. To
achieve this, the new DC UPS module UPS8600
uses the energy stored in BAT8600 battery
modules to keep the system up and running
in the event of a power failure, and it extends
the previous bridging times enabled by the
buffer modules from minutes to hours. The
PSU8600 has up to 36 outputs capable of
being adjusted between 4 and 28 volts, and
all of these can be buffered in the event of a
power failure. To maximise buffering time for
important loads, it is also possible to selectively
shut down certain outputs. The Sitop PSU8600
is particularly suitable for use in applications
that place stringent demands on reliability and
simple integration, such as the automotive,
food or pharmaceutical industries, and in the
field of plant and special-purpose machinery
building. The enhanced availability with the
new UPS8600 makes the power supply ideally
50 February 2019 www.instrumentation.co.za
suited also for process applications such as in
the chemical, oil and gas industries.
The DC UPS module can be simply
integrated into the system network of the
Sitop PSU8600 using the System Clip Link. The
battery module is installed by means of wall
mounting outside the network and connected
to the UPS8600 over a plus and minus wire and
the two wires of the Energy Storage Link. This
allows the system to automatically detect the
battery type and diagnose the battery charge
status. The smart battery management system
permits temperature-led charging, which helps
to extend the service life of the battery. The
battery modules are fitted with lead or lithium
iron phosphate batteries with a capacity of
380 Wh and 264 Wh respectively. Users are able
to connect up to five BAT8600 battery modules
to one UPS8600 to increase the mains power
failure bridging time. The BAT8600 battery
module using lithium technology offers a
particularly long service life, even at higher
ambient temperatures.
The supply is able to communicate with
practically any automation system at any
time through the base module, which has
Profinet and OPC UA capability. Users can
respond directly to messages and diagnostic
information about the operating mode (mains
or buffer operation), charge status, buffer
readiness, or the need to change a battery.
Integration in the network allows several PCs to
be safely powered down with the UPS8600.
Engineering takes place through the TIA
Portal, while diagnostic functions use WinCC
Faceplates or the Simatic PCS 7 Library. For
open integration over Ethernet or OPC UA, new
software is currently in preparation to enable
convenient system-independent engineering,
operation and observation.
For more information contact Jennifer
Naidoo, Siemens Digital Factory and Process
Industries and Drives, +27 11 652 2795,
jennifer.naidoo@siemens.com,
www.siemens.co.za

Rockwell Automation
expands power range
Rockwell Automation has expanded the power
ranges and capabilities of TotalForce technology
for its Allen-Bradley PowerFlex 755T AC drives.
The drives now offer an expanded power range,
helping engineers with applications from 7,5 to
4500 kW, improve productivity and reduce their
lifecycle costs. The expansion brings harmonic
mitigation, regeneration and common bus-
system configurations to a wider range of high-
demand applications.
Enhancements include more powerful
adaptive control capabilities, which allow the
drives to monitor machine characteristics
that can change over time and automatically
compensate for the changes that occur.
An adaptive tuning feature uses up to four
automatic tracking notch filters to block
resonance and vibration that can impact quality,
waste energy and prematurely wear out a
machine.
In addition, predictive maintenance features
provide real-time information about the
health of the drive. By monitoring operational
characteristics such as temperature, voltage
and current, the drive is able to calculate the
remaining life of critical components and notify
users. This allows users to act so unplanned
downtime can be prevented.
“TotalForce technology enables PowerFlex
755T drive users to take a proactive approach
in improving machine uptime,” said Adrian van
Wyk, Rockwell Automation Sub-Saharan Africa.
“The drives can deliver information about the
status of an application to the control system,
which can be critical for reducing downtime and
increasing productivity. In addition, the ability
CONTROL SYSTEMS
to be self-aware also enhances reliability and
simplifies service.”
The expanded power range makes
PowerFlex drives ideally suited for large
power applications, such as pumps and fans
requiring harmonic mitigation, and regenerative
applications requiring anti-sway functionality,
such as cranes and hoists. The offering includes:
• PowerFlex 755TL drive – the PowerFlex 755TL
drive uses active front-end technology and an
internal harmonic filter to reduce harmonic
distortion. The drive is now available from 7,5
to 1400 kW.
• PowerFlex 755TR drive – delivering power
from 7,5 to 4500 kW, this drive includes
both regenerative and harmonic mitigation
solutions. The drive helps reduce energy
consumption and costs by delivering energy
back to the incoming supply, resulting in a
more energy-efficient solution.
• PowerFlex 755TM drive system – this allows
users to build the system that best fits their
needs for regeneration and coordination
of multiple motors in common bus
configurations. To optimise their system
requirements and meet power-consumption
needs, users can select from a series of
predesigned modules with a power range from
160 to 4500 kW for motor side inverters and a
range of 70 to 4800 kW for regenerative bus
supplies.
For more information contact Adrian van Wyk,
Rockwell Automation, +27 11 654 9700,
avanwyk@ra.rockwell.com,
www.rockwellautomation.co.za
 CONTROL SYSTEMS
Eliminating the maintenance
backlog in record time
Adaptation concept facilitates the introduction of modern control systems and control technology.
There is a backlog in North-Rhine Westphalia
– a maintenance backlog. And not only
there: ageing chemical plants all over Europe
are in urgent need of modernisation. The
installed 19” technology and many outdated
process control systems must be exchanged.
Planners, system integrators, and operators
can obtain support from Phoenix Contact, a
company that provides not only device and
connection technology, but also components
for control cabinet and field installation as
well as consulting and engineering services.
In combination with specially developed
adaptors, this unique offering enables error-
free modernisation in record time.
Spares are becoming hard to find
Spare parts supply cannot be guaranteed
much longer. This unwelcome situation seems
like a wake-up call. Discontinued and obsolete
products in the field of automation technology
force operators of process engineering plants
to modernise their systems, which is often long
overdue anyway. In the meantime, significantly
more efficient products are available on the
market and succeed discontinued variants that
were used in old production facilities: modern
controllers, highly available and failsafe CPUs,
space-saving interface modules, and, of course,
powerful process control systems. So this is
not only about replacing old technology, but
also about designing the rejuvenation in a
52 February 2019 www.instrumentation.co.za
forward-looking way. On the one hand, it is
important to lay the foundation for increased
reliability and availability of systems; on the other
hand, it is necessary to make better use of the
space within the control cabinet to form a basis
for future enhancements. Many operators even
think ahead: together with the modernisation
they want to pave the way for meeting the
requirements of digitalisation as well.
All those who want to meet these
challenges and eliminate the maintenance
backlog in their systems want to do this with as
little effort as possible. The outdated systems
often produce commodities, or they are part
of a value added chain which manufactures
basic products for other systems in a
downstream process. That is why the system to
be modernised should only stand idle for the
shortest time possible. If it can be rejuvenated
during a scheduled shutdown, or even during
running operations, this will save time and
money. Mistakes must be avoided during
renovation as they would turn a scheduled
shutdown into unexpected downtime.
Modification with existing field wiring
Operators not only strive for keeping the costs
as low as possible, but also for minimising
shutdowns as much as possible. Many
operators also want to keep the existing field
wiring when modernising control engineering.
However, this means that when the new
technology moves in, the connections do not
fit any longer. Phoenix Contact offers system
cabling concepts that transfer field signals to
the new control system to ensure smooth and
error-free adaptation.
As an example, this was implemented for a
Trinseo Plastics production facility in Belgium.
The control technology and the 30-year old
control system were replaced. Within the
framework of this retrofit, the responsible
global process engineer, Wim van Drongelen,
together with Phoenix Contact, developed
a concept that ensures not only the fast
conversion of this site, but also of all other
Trinseo sites, which required modernisation
as well. A zero error-strategy was to be
implemented with as few I/O tests as possible.
Faster migration thanks to terminal
adaptors
The I/O cards of the new ABB S800 control
system were connected to field signals via
single wires. For this purpose, Trinseo used
the compact, passive termination boards
of the Varioface Professional VIP range. The
terminal strips on the field side were also to
be equipped with a high-position connector.
About 25 system-specific terminal adaptors
were generated and directly assembled on the
terminal strips. After setting up the new control
cabinets, the old single wires were removed,
the terminal adaptors were mounted and the

previously laid system cables were connected. 2500 I/O
signals were migrated this way. Due to the structured
system design, it was sufficient to test about 15 to 20
percent of the I/Os. The design saved two weeks of work
and accordingly, production started again earlier.
Just like Trinseo, many other companies are facing
the challenge of modernising their old control systems.
Most often, the 19” technology is replaced with a DIN
rail system. Often also Ex i signal conditioners, safety
relays, system cabling etc. are required, and sometimes
surge protection or SIL-certified technology. The
modernising companies benefit from the small size of
modern technology. Stephan Sagebiel, head of industry
management process engineering at Phoenix Contact,
affirms: “Generally, modern technology needs at least 30
percent less space than that from 20 years ago. This way,
space for future extension becomes available.”
From inventory to individual implementation
Phoenix Contact offers more than the required standard
technology. Needless to say, the company, after detailed
inventory and consulting, also supports engineering, if
desired. This is not only a benefit for end users. Planning and
service companies in charge of the migration of brownfield
systems can secure the special expertise of the automation
provider, which can avoid errors during the retrofit.
The development group, which makes sure that there
is an adaptor customised for the respective requirement,
is unique. The solutions developed for Trinseo are by
no means used for only one system. The conversion
from the Dow control system to the ABB system had to
be mastered in many other plants. “However, we can
even support migration to current control systems from
Siemens, Emerson, Yokowaga and other suppliers with
suitable adaptation solutions,” explains Sagebiel.
Phoenix Contact also supports the conversion from
Siemens S5 control technology to current S7 technology.
“Just pull out the S5 plug, remove the S5, install the
correct PCB adaptor in the rack, insert the S5 plug
and access the S7 via the adaptor,” outlines Sagebiel.
“This way, the existing field cabling can be kept during
modernisation.”
Migration openness for brownfield systems
The right overall concept is the crucial factor in terms
of the migration of brownfield systems. Old control
engineering can be replaced fast and without errors and
compact switching concepts ensure high signal density
and minimise the space needed for control. Sometimes,
though, solutions based on standard components are
not enough. Special adaptation concepts, as Phoenix
Contact provides them for all common control systems,
allow reacting to all local concerns of the prevailing
system. Thus, even a modernisation in running operation
is possible, as a retrofit in Wesseling shows.
For more information contact Sheree Britz,
Phoenix Contact South Africa, +27 11 801 8200,
sbritz@phoenixcontact.co.za,
www.phoenixcontact.co.za
EtherCAT measurement
modules extended
System-integrated precision measurement technology for
efficient machines and test benches.
The new ELM314x economy line of
the EtherCAT measurement modules
supplements the established ELM3x0x
line with a lower cost 1 ksps class. This
simplifies the use of the system-integrated
precision measurement technology, which
taps significant optimisation and efficiency
potentials both in production machines and
in inline test benches.
The new ELM314x measurement
modules are available in 2, 4, 6 and 8-channel
versions. High-precision measurements with
an accuracy of 100 ppm are possible – and
in a wide temperature range from 10 to 40°C
at that. Each channel of the measurement
modules can be set to current or voltage
measurements with a sampling rate of up
to 1 ksps per channel. Analog signals in the
ranges from ±1.25 to ±10 V, 0 to10 V, ±20 mA
or 0/4 to 20 mA can be processed.
The economy line offers considerably
reduced channel costs, but provides
the same wide range of functions as the
ELM3x0x line. These include freely adjustable
two-stage filters, oversampling, distributed
clocks, true RMS and scaler functions. The
extensive diagnostic features for unattended,
long-term use familiar from the ELM3x0x line
are also implemented.
Wide range of applications for 1 ksps
measurements
Sampling at 1 ksps per channel is
www.instrumentation.co.za February 2019
CONTROL SYSTEMS
suitable for a wide range of applications.
In particular, the processes of moving
machine components or final inspection
in inline test benches can be optimally
mapped with the economy line in
order to reliably control the processes.
Typical examples include part geometry
measurement on the fly, as well as fast, but
highly precise weighing procedures, e.g.
in bottling plants. In general, the ELM314x
EtherCAT measurement modules are ideal
for recording data from 10 V/20 mA sensors
and for feeding real-time information
directly back into the process. The speed,
reliability and accuracy of production
and test processes can be increased
significantly with these insights. Efficient
data logging for subsequent process
analysis and optimisation is also just as
easy. If increased requirements necessitate
higher sampling rates, the ELM3x0x
measurement modules with up to 50 ksps
can be used instead. These are suitable,
for example, for vibration measurement
on fast-running machines in order to
implement active vibration compensation
or predictive maintenance.
For more information contact
Michelle Murphy, Beckhoff Automation,
+27 11 795 2898,
michellem@beckhoff.com,
www.beckhoff.co.za
53
Rockwell Automation upgrades
control at Mozal Aluminium
Rockwell Automation has migrated the
control systems at Mozal Aluminium’s furnace
assembly and ladle cleaning shop to its modern
DCS based on the PlantPAx design standard.
An information-rich control architecture based
on the Allen-Bradley ControlLogix platform
helps to ensure improved long-term plant and
process performance and reliability, while also
bringing all the latest diagnostic and fault-
finding capabilities to these operational areas.
The migration included the rewriting of a
new, optimised control philosophy. The result
is a streamlined, consistent and coherent I/O
architecture visualised through the latest HMIs
and FactoryTalk Studio ME software, which
delivers intuitive, actionable machine data
and intelligence. Service teams now have far
greater insight into plant processes, allowing
faster, more efficient response to any point of
failure through added diagnostic features.
Additionally, both plant areas were
54 February 2019 www.instrumentation.co.za
upgraded to Device Level Ring EtherNet/IP
network architectures. This upgrade helped
to ensure no single, localised point of failure
in the network which can lead to more
widespread, unnecessary downtime. The
migration, for which Rockwell Automation
was responsible for the engineering, product
supply, integration, and commissioning, was
completed in twelve months.
Ladle shop
The ladle shop comprises three systems –
pre-heating, tube cleaning and ladle cleaning
equipment – which deliver rapid and efficient
automated cleaning and heating of the ladles,
and the distribution tubes that fill them. These
systems help to ensure that no bath material
and aluminium products can collect in the
ladles, which would reduce the integrity of the
molten aluminium, and thus the quality of the
final cast ingots.
The three upgraded ControlLogix
controllers supplied for these systems deliver
a rewritten I/O structure built on standards
and simplified control functionality. Detailed,
real-time visualisation and diagnostics of the
operation floor is provided by 16 PanelView
Plus 7 graphic terminals with FactoryTalk ME
V8.02 software.
The drive system on the tube cleaning
equipment was migrated to the Allen-Bradley
PowerFlex 755 AC Drive. In addition to
optimising energy efficiency, the PowerFlex
755 delivers a holistic level of actionable data
that simplifies fault finding and optimises
maintenance on the drive system.
“Upgrading the control systems on the ladle
shop floor was also an opportunity to provide
a complete inspection of the instrumentation
layer,” explains Devin Whitfield, lead engineer,
Rockwell Automation Sub-Saharan Africa.
“Working with Mozal, defective or unreliable

equipment was flagged, and related ad hoc
items of code added or removed.”
In an effort to ensure minimal disruption on
plant operations, each system was completed
within a planned three-day commissioning
period.
Furnace assembly
The casting process consists of 10 furnaces across
five casting lines, which maintain the aluminium
at a temperature of approximately 1000°C before
feeding it into a launder for casting.
Maintaining the optimum level of aluminium
in the launder during casting is critical: filling it
too quickly risks molten aluminium being ejected
from the launder – a significant safety hazard –
while an inadequate flow results in under-cast
ingots of inferior weight, size and quality.
Controlling the tilt demand, internal
temperature and casting temperature of the
furnaces is now achieved via PID control through
the ControlLogix platform. The approximately 200
I/O control system automates both the position
and speed of the furnace tilt, and integrates
Yokogawa adds OpreX redundancy
Yokogawa has announced a platform
that enables software packages to run on
general-purpose computers in a redundant
configuration, which has been added to its
OpreX Control and Safety System family.
This redundancy software will help raise the
availability of all the solutions that make up
Yokogawa’s OpreX Control category of systems,
software, and devices. The first software
packages based on this platform are the
Exaopc OPC interface package and the Exapilot
operation efficiency improvement package. For
enhanced availability in plant operations, the
company plans at a later date to incorporate
this redundancy software in other packages
that make up the OpreX Control family.
Industrial infrastructure depends on
highly-reliable systems to keep it running even
when a fault occurs. Such systems often have
redundant features, like a hardware control
unit with the same functional capabilities that
stands ready to take over in the event of a fault
in the primary hardware. Yokogawa’s Centum
VP integrated production control system,
ProSafe-RS safety instrumented system, and
Stardom network-based control system, all
achieve high availability and reliability, thanks
to the use of such redundant hardware.
Manufacturing execution systems (MES)
and other types of applications typically run on
a general-purpose PC that is not set up for use
with existing third-party furnace sub-systems
including the burner management systems,
tightness control and hardwired safety systems.
In order to execute the migration without
affecting production, Rockwell Automation
installed the control system within the casting
and maintenance schedule of each furnace. “With
production demand in the cast house requiring
four of the five casting lines active at any one
time, and only one of two furnaces casting for
each line, we installed and commissioned the
control of each furnace in a narrow, time-critical
window,” explains Coenraad Maree, project
engineer, Rockwell Automation Sub-Saharan
Africa.
This required not only a high degree of
efficiency and accuracy to help ensure each
system migration did not extend beyond
scheduled windows, but also a flexible approach
in accommodating any changes to the respective
schedules.
The biggest installation challenge,
however, was that of working in the intense
heat of the cast house environment. With
with another PC in a redundant configuration.
To accomplish that, it is necessary to either
install some kind of dedicated hardware or add
a function to the PC software.
Many end-users have expressed an
interest in a solution that would enable them
to achieve a redundant configuration at a
reasonable cost. To satisfy this need, Yokogawa
has developed its new software platform.
Features
High availability
If a fault occurs, the software initiates a
transfer of control from the active PC to
the standby. This takes no longer than one
second to complete, well within the operating
parameters of oil, petrochemical, chemical, and
other process facilities, where the collection
of data and the issuance of control commands
CONTROL SYSTEMS
ambient temperatures of over 40°C, safety
of the commissioning teams was a critical
consideration.
A preferred automation supplier
In addition to the migration of the casting
furnaces and the ladle shop to the improved
software standard, Rockwell Automation
simultaneously executed a plant-wide
technology migration of Mozal Aluminium’s
drive network to the PowerFlex 755 platform.
This project numbers over 350 drives in total,
which will be complete in November 2020.
This modern, Connected Enterprise-ready
distributed control system helps secure the
long-term reliability of the production plant,
and amplifies the level of plant and system-
wide intelligence available to onsite operation
and maintenance teams to improve efficiency
and reduce unplanned downtime.
For more information contact Devin Whitfield,
Rockwell Automation, +27 11 654 9700,
dwhitfield@ra.rockwell.com,
www.rockwellautomation.co.za
based on that information typically takes
a few seconds or more. Since the data and
status information on the two PCs is always
synchronised, processing can continue
without interruption, even when the system
is performing sequential control of multiple
tasks. This feature minimises the probability
of any loss of data and ensures there is no
interruption in control. The software thus
ensures high availability of the systems that
make up a vital part of industrial infrastructure.
Long-term operational support with online PC
replacement
PCs often remain in use for years in plants
and need to be replaced when they grow
outmoded or fail. Thanks to this software which
enables applications to run in a redundant
configuration, an outmoded or defective PC
can be replaced while the system remains
online. It is even possible to operate different
PC models in a redundant configuration
providing they have been tested and approved
by Yokogawa, which helps users operate their
systems stably over long periods of time and
improve productivity.
For more information contact Eugene Podde,
Yokogawa South Africa, +27 11 831 6300,
eugene.podde@ao.yokogawa.com,
www.yokogawa.com/za
www.instrumentation.co.za February 2019 55
 CONTROL SYSTEMS
Bosch Rexroth introduces latest
transfer system
By optimising existing components and
integrating new modules into its TS 5 conveyor
system for heavy loads, Bosch Rexroth has
enhanced its already impressive flexibility to
meet the requirements of an even broader range
of industry sectors. The new capabilities include
tandem transport for oversized cargo, which is of
particular importance to users in the automotive
sector. The TS 5 can now also connect with i4.0
tools, to visualise production processes in real-
time, and, with the MTpro design planning tool,
can achieve any layout for loads of over 400 kg.
In the latest generation, Bosch Rexroth has
expanded on the roller conveyor system’s known
strengths by developing new modules that
users can combine in any configuration they
choose. With the new conveyor, customers can
now integrate a 3-way diverter, a rotate unit, a
front-end drive, and a compact stop gate into the
final system. For larger components, the tandem
ABB unveils latest DCS upgrade
Originally launched in 1994, Freelance is ABB’s
DCS solution for process industries. It combines
the advantages of a DCS with the PLC, and is
characterised by ease-of-use, scalability, flexibility
and reliability. Freelance 2019 is the latest version
of the DCS.
New features and benefits of Freelance
2019
Improved usability: provides a significant increase
in efficiency and usability for its Operations
and Engineering solution by adding advanced
navigation, filter and sort functionality. The user
experience has been improved through the
modern user interface.
Scalable: a new controller, PM 904F, expands
the Freelance AC 900F controller family in the
upper range, supporting four communication
56 February 2019 www.instrumentation.co.za
transport capability allows for the transfer of
excessively long products.
The upgrades provide the user with even more
flexibility when designing their individual system
layout and make the TS 5 the ideal solution in a
broad range of industry sectors. Other advantages,
such as ESD capability, suitability for abrasive or
oily environments, or use in a dry room, further
enhance the variety of applications optimised by
the conveyor system.
Compared with standard chain drives, the
system’s king shaft drive and the conveyor
rollers allow customers to experience virtually
maintenance-free production, with low wear and
increased productivity.
Transfer system meets Industry 4.0
The conveyor also sets a benchmark in terms
of digitalisation: the system can be seamlessly
connected to other Rexroth solutions such as the
interfaces. It also provides more application
memory and enables the reservation of specific
memory. As for all Freelance controllers, user
applications are 100% runtime-compatible,
which also enables smooth upgrade
opportunities.
More connectivity: up to four monitors
can now be connected to a single operator
workplace. The available display types per
monitor, as well as the arrangements of the
monitors, are easily configured and fulfil the
typical requirements for occupational safety and
operator effectiveness.
Enhanced security: Freelance provides an
additional alternative to its user management
capabilities, known as Security Lock, via a solution
called Extended User Management. This new
option makes use of Windows user accounts,
ActiveCockpit. The interactive communication
platform processes and displays manufacturing
data in real time. Parameters such as energy
efficiency, cycle time and work piece pallet
tracking can be measured and visualised
for greater transparency and more efficient
production processes.
Finally, the MTpro project planning tool
simplifies every part of the project with its easy
layout design, automated order lists and links to
the product catalogue and assembly instructions.
This means that the transfer system can be
planned and implemented even faster, further
shortening time to market for manufacturers who
depend on TS 5.
For more information contact Jonathan Narainsamy,
Tectra Automation, +27 11 971 9400,
jonathan.narainsamy@tectra.co.za,
www.hytecgroup.co.za
supporting both local and domain accounts. As a
result typical requests for options such as central
password management, rules for password
complexity, or password ageing can be fulfilled.
Compatibility: Freelance 2019 can run on
Windows 10 and Windows 7 in the same system
architecture. This allows customers to do a step-
wise upgrade to modern IT infrastructure which
helps in reducing maintenance costs.
As in earlier versions of Freelance, customers
have the option of staying automatically up-to-
date by subscribing to the Automation Sentinel
life cycle program by, for example, providing
automatic cyber security patches.
For more information contact
ABB South Africa, +27 10 202 5212,
leo.franken@za.abb.com, www.abb.com/za
 DURABILITY
AND PRECISION
MEASUREMENT
Bright LED status indicators
Push-button programming
Two-line, eight-
character display

User-configurable discrete
NPN/PNP output
Analog output is 4-20 mA or
0-10 V depending on model

Class 2 laser emitter

Small, highly visible spot
IP67-rated zinc housing

www.retautomation.com
www.turckbanner.co.za

LTF Series Time of Flight Laser Distance Sensors are

designed to accurately measure targets at distances up
to 12 meters. They provide reliable detection regardless
of colour or material, even at an angle, providing a reliable
solution for challenging targets. They solve a broad range
of industrial measurement applications, including part-in-
place, part profiling and positioning, and roll diameter and
web tension control.

RET Automation Controls (Pty) Ltd

Turck
P.O. Box Banner (Pty)
8378 | Edenglen Ltd
1613 www.instrumentation.co.za February 2019 57
© 2016 Banner Engineering Corp., Mpls, MN USA sales@turckbanner.co.za | Phone: +2711 453 2468
Phone: 011 453 2468 | sales@retautomation.com
 CONTROL SYSTEMS
One machine control over EtherCAT
Manufacturing is changing. Production lines
need to be increasingly flexible to cope
with shorter production runs, more varied
products and tighter deadlines. Manufacturers
are addressing these challenges with more
advanced, interconnected and intelligent
systems that can be programmed to handle a
variety of tasks.
This has brought new challenges, such
as how to program all these devices without
needing to learn many different systems and
programming languages. Fortunately, there
are tools out there such as Omron’s Sysmac
Studio that offer fully integrated development
environments (IDE) for configuration,
programming, monitoring and 3D simulations.
The machine controller used comes standard
with built-in EtherCAT.
The EtherCAT network can be accessed
with one connection and is the perfect match
between fast real-time machine control and
data plant management.
”One machine control over EtherCAT
through one connection and one software is
how we define Omron’s Sysmac automation
platform,” notes Omron product manager, Evert
Janse van Vuuren. Omron’s EtherCAT solutions
include products for logic, motion, safety,
58 February 2019 www.instrumentation.co.za
robotics, vision, information, visualisation and
networking, all under one software.
Accurate positional information over
EtherCAT
Recently, Omron partnered with an OEM, one
of the top three end of line machine solution
providers in Africa, to install a system at a
multinational end user plant. The customer
required an automated solution to the current
manual packing method currently being used. It
was suggested by the Omron product manager
that the company should deploy Omron Delta
robots to pick and place the bottles from a
moving puck conveyor and precisely pack the
bottles onto a moving tray.
With no vision system being used, it was
decided to use two servo systems for feedback
on the position of the trays and the pucks.
“The robots synchronise with latched
positional data from both the puck and the tray
conveyor systems and pick and place relying
on the accurate positional information coming
from the EtherCAT network,” explains Janse van
Vuuren.
The pick and place robotics machine is
one of five smart machines that complete this
specific line. The bottles are filled, labelled and
inspected before the Omron robotics system
pick and place the filled bottles into pack trays.
The final product is filled roll-on bottles that are
shrink wrapped at the last machine in sets of
six, to be transported to the distribution facility,
from where it is sent to various selling points.
What makes this so remarkable is the
seamless integration between Sysmac and
EtherCAT that results in the extraordinary speed
and accuracy of the system, which provides a
complete automated solution to the packaging
of bottles, directly from the tray, after being filled.
For this specific project, three Delta robots
were used, each having three EtherCAT servo
axes controlled as a group. The communications
network used between the servo axes and the
master robotics controller is EtherCAT.
“At Omron, EtherCAT is used because of its
network speed,” concludes Janse van Vuuren.
“EtherCAT offers high speed communications
between the master controller and actuators or
sensors, which is crucial in motion control and
robotic applications.”
For more information contact Omron
Electronics, +27 11 579 2600,
info.sa@eu.omron.com,
www.industrial.omron.co.za
 CONTROL SYSTEMS

Four questions to ask when

­choosing a vision solution
Many users find vision systems challenging
and it can be difficult to know where to
start, but there are some simple steps that
can help to match the right vision solution
to an application. This article describes four
questions to ask to help clarify the application
requirements.
Vision sensors and smart cameras are some
of the most accessible vision technologies,
especially for those just getting started
with implementing vision solutions in their
manufacturing processes. The following
questions can help evaluate the application
requirements before making a decision:
1. What is the speed of the application? It is
important to verify that the vision solution
is suited to the speed of the application. The
more conditions that need to be inspected,
the longer the inspections will take.
2. What is the distance from object to sensor?
How far away from the objects will the sensor
be mounted? A vision sensor should typically
be mounted less than 300 mm away from the the question where many people struggle Next steps
target. For further distances, a higher-end when getting started with vision. They know After answering these questions, the next step
system may be required. they are looking for a ‘good’ condition, but is to try out a solution. Every vision application
3. What size objects are being inspected? Make what counts as good? What are the true is unique, and it is best to try out the device
sure that the object(s) fit within the viewing pass/fail requirements? For this, evaluate the under real-world conditions to make sure it
window of the vision sensor. Note that tolerance for less than perfect parts. One way works for the application. Finally, partner with
vision sensors have a more limited field of to do this is to find the ‘best’ bad’part and a manufacturer that offers both vision sensors
view compared to more expensive vision the ‘worst’ good part and set the tolerances and smart cameras, which makes it simpler to
solutions. Therefore, vision sensors work for the sensor at both ends of the spectrum. upgrade if needed.
best for small parts, or assemblies with small Setting tolerances is essential for any vision
quantities of parts. If a wider field of view application and will help ensure minimum For more information contact
is needed, a smart camera may be a better wastage of parts and material through Brandon Topham, Turck Banner,
option, offering more functionality while still rejecting parts that should be considered +27 11 453 2468,
being easy to commission and use. passable – or allowing parts through that brandon.topham@turckbanner.co.za,
4. What conditions are being inspected? This is should have been rejected. www.turckbanner.co.za

www.instrumentation.co.za February 2019 59

 CONDITION MONITORING
AST’s line-type heat sensing
Alien Systems & Technologies (AST) offers a
wide range of automatic fire detection systems
from advanced ultra-smart addressable
point type detection systems to regular
conventional systems. It also offers specialised
conveyor belt/moving fire black body infrared
detectors, along with the ProReact line-type
heat sensing cable – otherwise known as
linear heat detection (LHD) cable.
Sensing fire conditions using cable
Broadly speaking there are two methods
to sense fire conditions using cable. Most
commonly used in the South African market
is the digital type method: essentially this
type of cable looks for a short circuit as a
means of triggering an alarm condition. The
cable is comprised of two conductors, each
surrounded with an insulator that is designed
to melt at a certain temperature. Both these
conductors are then twisted and remain under
torsion. This twisted pair of conductors is then
sheathed either in a standard PVC sheath or
with options of UV protection (nylon) and/or
mechanical protection (stainless steel braid) or
chemical resistant (polypropylene) sheaths.
Digital types
The standard digital type linear heat sensing
cable comes in a range of temperature trigger
point options from 68°C to 185°C. These
60 February 2019 www.instrumentation.co.za
cables are known as ‘digital’ because they are
‘off’ below the activation temperature and
irreversibly switch ‘on’ when the activation
temperature is reached. The primary advantage
of using line type detection is that the
mechanism can be spread over an application,
bringing it closer to the source of the fire
and thereby improving response times over
traditional point type heat detecting devices.
The entire linear detection range is UL listed
UL521 and FM approved.
A UL approved digital interface monitor
module (DIMM) is available to provide
accurate alarm location along the LHDC cable,
as well as additional benefits when used in
conjunction with ProReact Digital LHD cable.
The ProReact DIMM is designed to enhance
the functionality of existing or new digital LHD
systems by monitoring up to two zones. A
unique interlock/coincidence detection mode
eliminates the possibility of false alarms by
requiring both LHD cables to trigger before an
alarm is transmitted. A built-in digital display
shows the state of each zone, including the
exact distance in metres to the alarm point. It
also includes an RS-485 Modbus RTU output for
integration with a PLC or scada system.
AST also offers specialised digital type
cable of the low smoke zero halogen type.
This variant is UV stable with a hydrocarbon
resistant coating that minimises the release
of smoke and harmful emissions in the event
of a fire. The cable is also flame retardant and
oil and fuel resistant ensuring it can be used
in harsh environments. Inherent UV stability
means it is suitable for indoor and outdoor
applications. This cable is also UL/FM approved.
In addition, another variant known as
ProReact very high temperature (VHT) digital
LHD cable is designed to detect overheating
and fires in environments that are normally
exposed to extremely high temperatures.
The cable has an activation temperature of
230°C and can withstand continuous ambient
operating temperatures of up to 170°C.
ProReact VHT digital LHD cable is approved in
line with UL521 and FM Class 3210 standards
and is fully RoHS compliant. It is also used in
conjunction with automatic fire extinguishing
systems in engine compartments and floating
roof tanks.
Analog types
The second method of sensing a fire with cable
is to use analog linear heat detection cable.
This method continuously responds to changes
in temperature and the technology offers the
facility to program an early warning pre-alarm
as well as the specified alarm temperature. If
the temperature surrounding the ProReact
analog LHD cable reaches the pre-alarm point,
the control unit triggers a warning giving the
 CONDITION MONITORING

user time to survey the area at risk. Only when
the temperature reaches the specified set
alarm point will the control unit trigger a full
alarm. The optional two-stage programmable
alarm setting makes this method of overheat
detection flexible and ideal for use in a
variety of environments and applications. The
technology automatically compensates for
changes in ambient temperature to maintain
the accuracy of the alarm temperature as well
as offering up to 500 metres of continuous
detection per control unit.
The ProReact analogue LHD cable is
resettable which means it is not always
necessary to replace the cable after an incident.
Once the alarm has been triggered, and
depending on the severity of the incident, the
system can simply be reset with minimum
disruption and inconvenience.
Applications for linear heat sensing cable
include conveyor belts, in-rack sensing for
warehousing storage, both floating roof and
fixed roof petro-chemical tanks, cold storage
areas, tunnels, electrical cable runs, car parks
and escalators.
Rate of change types
AST also offers a unique ProReact linear rate
of change cable sensing system that has
been specifically designed to detect liquefied
natural gas leaks. The combination of a highly
sensitive cable and control unit uses advanced
digital signal processing to detect a rapid
change in temperature. The nature of its
intended application demands that the system
is sufficiently robust to withstand a range of
hazardous environments. This system is simple
to install and designed to integrate into any
building management system. It continually
adjusts to changes in the surrounding
environment to maintain a high level of
sensitivity, which eliminates false alarms and
guarantees rapid response to an incident. The
technology offers a versatility and functionality
not readily available in liquid natural gas
facilities and is designed to enhance existing
detection systems and provide early warning
of abnormal situations. The cable is also self-
restoring after an incident allowing the system
to be reset rather than replaced. It is qualified
for use in hazardous areas (ATEX/IECEX zones 0,
1 & 2; Gas Group IIC; T Class T5).
For more information contact Alien
Systems & Technologies, +27 11 949 1157,
sales@astafrica.com,
www.astafrica.com

Emerson drives faster response times

Emerson has released AMS Inspection Rounds,
a new application for the AMS Trex Device
Communicator that will make it easier for
operations teams to capture, report and
respond to abnormal plant conditions that
pose risks to reliability, safety, and performance.
The new application allows personnel to record
field condition data and automatically deliver it
to other plant systems where decision makers
can drive effective action.
Most plants rely on manual inspection
rounds to detect abnormal plant conditions
not identified by sensors. With AMS Inspection
Rounds, operators on rounds can electronically
record any abnormal or hazardous conditions
immediately, such as unusual equipment noise,
spills, smells, excessive corrosion and safety
hazards. Condition data can be entered on the
ruggedised AMS Trex in real-time, timestamped
for compliance and audit requirements. The
system delivers condition data to other plant
systems via a wired or secure WiFi connection,
eliminating the need for manual entry. It also
provides automated workflows to operations
and maintenance personnel while they are in helps ensure that issues impacting safety and of audit trails freeing personnel to focus
the field, ensuring complete, consistent, and reliability are detected, reported, and resolved on more important tasks. Operations and
repeatable collection of condition data. earlier.” maintenance teams can also access historical
“Route-based inspections are a key line of With clear dashboards of routes, status, data to identify and eliminate the root causes
defence for identifying abnormal and unsafe alerts, and action items, users can identify, of recurring problems.
conditions that may reduce efficiency or put schedule and coordinate steps for resolving
personnel in danger,” said Mani Janardhanan, issues more quickly. Electronic recording For more information contact Rob Smith,
vice president of product management, of route data saves the many hours of time Emerson Automation Solutions,
Plantweb and reliability solutions, Emerson typically lost in transcribing paper notes to +27 11 451 3700, rob.smith@emerson.com,
Automation Solutions. “AMS Inspection Rounds electronic media, and simplifies the generation www.emerson.com

www.instrumentation.co.za February 2019 61

Steam system inspection technology
Steam is used to heat raw materials and treat
semi-finished products. It is also a power
source for equipment, as well as for heat
and electricity generation. But steam is not
free. Annually, it costs millions to feed the
generation boilers.
Generally speaking, steam is an efficient
way to transport heat energy because the
amount of latent heat required to produce
steam from water is quite large, and it is easily
moved in pressurised piping systems that can
deliver that energy at manageable costs. When
steam gets to its point of use and gives up
its latent heat to a process, it condenses into
water, which must be returned to the boiler for
re-conversion to steam.
Several condition-monitoring technologies
are useful for monitoring steam systems to
determine how well they are functioning.
Among those technologies is infrared (IR)
thermography, in which technicians use
thermal imagers to capture two dimensional
images of the surface temperatures of
equipment and structures.
Thermal images of steam systems reveal the
comparative temperatures of system components
and thereby indicate how effectively steam system
components are operating.
What to check
Using a combination of ultrasound and
thermal inspection significantly increases the
detection rate of problems in steam systems.
Check all steam traps and steam transmission
lines, including any underground lines. In
addition, scan heat exchangers, boilers and
steam-consuming equipment. In other words,
examine every part of the steam system with a
thermal imager.
62 February 2019 www.instrumentation.co.za
Steam traps are valves designed to remove
condensate as well as air from the system.
During inspections, use both thermal and
ultrasonic testing to identify failed steam traps,
and whether they have failed open or closed.
In general, if a thermal image shows a high
inlet temperature and a low outlet temperature
(< 100°C) that indicates that the trap is
functioning correctly. If the inlet temperature is
significantly less than the system temperature,
steam is not getting to the trap. Look for an
upstream problem – a closed valve, pipe
blockage, etc. If both the inlet and outlet
temperatures are the same, the trap probably
has failed open and is ‘blowing’ steam into
the condensate line. This keeps the system
operating but with significant energy loss. Low
inlet and outlet temperatures indicate that the
trap has failed closed and condensate is filling
the trap and the inlet line.
Also use the thermal imager to scan steam
transmission lines for blockages, including
closed valves, and underground steam lines for
leaks, heat exchangers for blockages, boilers,
especially their refractories and insulation, and
steam-using equipment for any anomalies.
Consider creating a regular inspection route
that includes all key steam-system components
in the facility, so that all traps are inspected
at least annually. Larger or more critical traps
should be inspected more frequently, as the
potential for loss is greater. Over time, this
process will help determine whether a hot or
relatively cool spot is unusual or not and help
to verify when repairs are successful.
What represents a ‘red alert’?
Water boils at 100°C making steam, which
is routinely transmitted at high pressure,
extremely hazardous, so any condition that
poses a safety risk should take the highest
repair priority. In many situations, the next
most important kinds of problems to deal
with are those that can affect production
capabilities.
The cost to an operation that completely
loses its steam system varies from industry to
industry. Among the industries that use the
most steam are chemicals, food and beverage
processing and pharmaceuticals. If the facility
has performed no maintenance of steam
traps for three to five years, expect 15 to
30 percent of the traps to have failed. So,
if there are 60 medium-sized traps on the
system, losses from ‘blow by’ are estimated
to be between R0,5 million and R0,85 million
annually.
To check steam trap performance, sight,
sound and temperature are the dominant
techniques. Implementing a basic annual
inspection of the steam traps and associated
equipment with infrared inspections will
likely reduce steam losses by 50-75%.
A sensible approach to a steam system
management programme is to establish
repair priorities based on safety, steam/energy
loss and possible impact on production and
quality. Whenever a problem is discovered
using a thermal imager, use the associated
software to document the findings in a report,
including a thermal image and a digital
image of the equipment. It is the best way
to communicate the problems found and to
suggest repairs.
For more information contact Comtest,
+27 10 595 1821, sales@comtest.co.za,
www.comtest.co.za

New app scans TeSys GV4 circuit breakers
Schneider Electric has released a TeSys GV4
multifunction mobile app that connects
to its new TeSys GV4 motor circuit breaker
to provide basic and advanced protection
settings configuration, using a near field
communication (NFC) interface.
The technology of the GV4 circuit breakers
offers advanced protection with ratings of up
to 115 A with service breaking capacity (Ics) of
25 kA/400 V (B series), 50 kA/400 V (N series)
or 100 kA/400 V (S series). “The electronic core
of GV4 gives a greater detection accuracy,
with alarm and advanced protection,” explains
Christo Kotze of Schneider Electric South
Africa. “The multifunction motor protection
GV4, with advanced adjustable functions, may
be equipped with one or two SDx alarm/fault
differentiation modules to prevent trips, or to
identify the type of fault after a trip.”
Power connections and basic functions
The breakers are fitted standard with 2-hole
EverLink power connectors and creep
compensation, for bare copper cables. “This
patented Schneider Electric technology makes
it possible to achieve accurate and durable
tightening torque in order to reduce the risk
of cables working loose due to creeping.
Resistance to vibration is improved and periodic
re-tightening is no longer needed,” adds Kotze.
Basic functions include:
• Short circuit protection to against an
instantaneous trip of the circuit breaker: tripping
is achieved through a magnetic element
incorporated in the motor circuit breaker or by
Safe infrared inspections under load
Iriss and Eaton joined forces to manufacture the
Pow-R-Way III Busway System, which enables
safe and accurate energised infrared inspections
under full load. The UL listed joint cover design,
with the polymer infrared window, enables
Pow-R-Way III users to perform critical condition-
based maintenance inspections of busbar joint
connections, inclusive of infrared, ultraviolet and
visual inspection. This Busway System allows
infrared inspections to be conducted, safely, at
any time, while the ruggedness of the joint cover
with the polymer window is uniquely designed
for industrial environments where mechanical
stresses are common.
For more information contact R&C
Instrumentation, +27 11 608 1551,
info@randci.co.za, www.randci.co.za
electronic detection (GV4 and GV7).
• Overload protection: this is obtained by
means of a thermal element incorporated
in the motor circuit breaker, or by sensors
for electronic products (GV4 and GV7).
An automatic compensation for ambient
temperature variations is also provided.
• Motor On/Off control: provides a local
manual control of the motor when used on
its own (without a contactor). Operation is
possible by toggle or a single rotary handle.
• Contacts position indication: the circuit
breakers accurately indicate the position of
the moving contacts.
Advanced modules
Additional functionality can be achieved
through advanced modules:
• Under voltage protection: trips the circuit
breaker in the case of under voltage, which
protects users against sudden starting of the
machine when normal voltage is restored.
• Remote off power: the breaker can be remotely
tripped with the addition of a shunt trip.
• Off locking: both open-mounted and
enclosed motor circuit breakers can be
locked in the off position by up to 3 padlocks.
In addition to basic protection, GV4 also
embeds protections against:
• Long start (high inertia, resistive torque
machines).
• Jam (over torque, machine failure).
• Ground fault (reduced isolation).
• Unbalance (phase currents not equal) and
phase loss (1 or 2 phases missing)
CONDITION MONITORING
IIoT features
Fully configurable advanced protection
includes Ecoreach software on a computer
connected to the test socket through a
configuration and maintenance module,
and the wireless application on Android
smartphones through NFC.
Available only as an Android app, through
Google Play Store, the app can:
• View and configure protection settings.
• View alarms and basic device information.
• Check fault history to speed up maintenance.
• Scan existing protection settings, device
information and alarms.
• Modify settings and apply them to the device.
• Clear alarms on the device.
• Save settings as templates for copy to
multiple devices.
• View history of all scanned devices.
“When engineers come to differentiate
between motor circuit breakers versus fuse
protection, they need to consider that circuit
breakers are a common solution for protecting
motors against short circuits and overloads,”
concludes Kotze. “As a comparison, a fuse-
based solution can only provide a partial
protection, depending on the choice of the
fuse type and rating. The thermal magnetic
circuit breaker is adjustable and can be fine-
tuned to the actual motor load.”
For more information contact Prisca Mashanda,
Schneider Electric SA, +27 11 254 6400,
prisca.mashanda@schneider-electric.com,
www.schneider-electric.co.za
www.instrumentation.co.za February 2019 63
SKF runs on predictive maintenance
There is an ever-growing need for faster, more efficient production
methods and manufacturers are striving to find the perfect balance
between product quality and affordability and to deliver within the
shortest possible lead times, while acknowledging the environment.
This quest, amongst other factors, has given rise to the fourth
industrial revolution which sees manufacturers adopting the latest
automation and digitalisation technologies to streamline their
production processes.
SKF, always at the forefront of innovation, started the digital
transformation of its Göteborg plant in Sweden in 2015. The bearing
and rotation technology specialist is addressing every aspect within
the digital revolution space in order to arm its facility with the
necessary capabilities for the seamless, efficient, cost-effective,
safe and eco-friendly production of bearings of exceptional
quality.
With process fluidity a key factor in SKF’s digital transformation,
the company has also turned its attention to enhancing control
over its production and operating systems through the constant
monitoring of equipment used in the manufacturing process.
Combatting unexpected machine failures is essential to reduce the
risk of production downtime with subsequent massive costs incurred
as a result of production losses, decreased productivity and critically,
long lead times.
Wireless sensors enable predictive maintenance
The company therefore took the decision to adopt a digital predictive
maintenance approach to ensure a continuous process flow and
created an innovative network of wireless sensors to monitor the
most critical machines.
The sensors, which are inside an IMx-8 box, capture and analyse
data from the industrial equipment in real time and alert operators of
any problems to avert costly equipment failures. Monthly production
halts are now a thing of the past; intervention is done in a graduated
way every two or even three months without greatly affecting
work flow.
SKF has developed a nomad solution called QuickCollect to
64 February 2019 www.instrumentation.co.za
monitor the remaining machines. This portable sensor, which is the
size of a mobile phone, can be fixed to strategic points on certain PLCs,
making it possible for anyone to monitor machine health without the
need for extensive training or diagnostic expertise. Results such as
temperature, rotation speed and vibrations are displayed directly on
the operator’s mobile phone. Combining an easy-to-use sensor with
mobile apps, machine condition can be quickly and easily identified
and inspection, process and machine health data can be shared
company-wide. These latest-generation sensors gather new forms
of data such as impact detection and provide advanced levels of
information which in the past operators were unable to access.
To further improve flexibility, SKF has also introduced processes to
simplify machine configuration that speeds up switch-over between
tasks. Re-initialisation on the old lines, which required between four to
eight hours, has today been reduced to around one hour.
New data processing algorithms and artificial intelligence are
being explored to assist in the early detection of failures. In the future,
massive amounts of data will be gathered and saved either locally or
in the cloud according to how urgently the data is needed. To ensure
optimum use of the data and to meet pre-set goals, it will be important
to determine what information must be processed. The training
of operators has been imperative so that they can understand the
complete architecture to establish if, for example, a failure comes from
the network, the MES, or higher up. The responsibility will fall on the
upskilled operators to initiate the correct procedures.
SKF’s digital transformation has already seen the replacement of
the Göteborg plant’s four conventional production lines (each line
was only able to manufacture one bearing type), with a single, almost
completely automated Industry 4.0 production line that can deal
with different bearing sizes and selections. SKF’s digital revolution
encompasses a range of solutions including industrial robots and
automatic guided vehicles.
For more information contact Samantha Joubert,
SKF South Africa, +27 11 821 3500,
samantha.joubert@skf.com, www.skf.com
 CONDITION MONITORING

The Fluke 810 vibration

tester for condition monitoring
Vibration, on a basic level, is just an oscillation
of machines and components in motorised
equipment. Sometimes it is a symptom or even
a cause of trouble; other times, it is part of
normal machine operation. Oscillating sanders
and vibratory tumblers, for example, rely
on vibration in order to function. In internal
combustion engines and gear drives, vibration
is to an extent unavoidable. However, most
devices are engineered to avoid vibration. Left
unchecked, vibration can cause damage or
deterioration to equipment over time.
A number of factors can cause vibration.
Unbalance occurs when a ‘heavy spot’ develops
in a rotating component. The effects of
unbalance increase along with machine speed
and can reduce bearing life or cause machine
vibration. Misalignment or shaft runout is
when machine shafts are not in line. This can
happen during assembly, or develop over
time as a result of thermal expansion, shifting
components or improper reassembly following
maintenance. Vibration can be radial, axial
or both. Wear can produce vibration when
components such as bearings, drive belts or for immediate attention. Equipped with a basic blowers, drives, gearboxes, couplings, pumps,
gears become worn or damaged. A heavily understanding of vibration and its causes, compressors and spindles.
worn or chipped gear tooth, for example, can along with the Fluke 810 Handheld Vibration More than just a vibration detector,
cause vibration. If a vibrating component has Tester, plant maintenance professionals can the 810 offers maintenance professionals
loose bearings or is loosely attached to its quickly and reliably find the root and the comprehensive diagnostics and problem
mounts, it can become destructive through severity of machine vibration and determine solving. The diagnostic technology analyses
added wear and fatigue. whether there is cause for service or repair. machine condition and identifies faults by
Vibration can accelerate machine wear, The Fluke 810 Handheld Vibration Tester comparing vibration data to an extensive set
consume excess power and result in other provides information on equipment, without of rules and algorithms developed over years
severe side effects such as safety problems requiring extensive monitoring over the of field experience. It determines fault severity
and worsened plant working conditions. It can long term. The advanced handheld device is by simulating a fault-free condition and
even damage equipment to the extent that designed and programmed to discover and establishing a baseline for instant comparison
it must be taken out of service, halting plant diagnose common mechanical problems. It to gathered data. Thus every measurement is
production. can detect vibration along three planes of essentially compared to a ‘like new’ machine.
When measured and analysed properly, movement and provide a plain text diagnosis When a fault is detected, the Fluke 810
however, vibration can play an important role with a recommended solution. identifies the problem, along with its location
in preventive maintenance programmes. It The Fluke 810 helps maintenance and severity, in order to help maintenance
can serve as an indicator of machine condition professionals determine machine condition professionals prioritise necessary maintenance
and allow plant maintenance professionals and get to the root of problems quickly. It fills tasks. It also recommends repairs and uses
to act before damage or disaster strike. When the gap between high-end, complex vibration context-sensitive on-board help to provide
analysing vibration, variables such as direction analysers, and low-end vibration pens, which users with guidance and tips in real time. This
(fradial or axial) and amplitude (severity) sacrifice accuracy for cost and ease of use. The precision allows maintenance teams to act
should be taken into account. Another factor to Fluke 810 offers the diagnostic capabilities of when needed to keep mechanical equipment
consider is frequency, which is how often the the high-end analysers, along with the speed in peak condition and to keep facilities
machine moves back and forth as a result of and convenience of the lower-end testers, at a productive.
the factors that are causing the vibration. reasonable price. It is programmed to diagnose
It is important for plant maintenance unbalance, looseness, misalignment and For more information contact Comtest,
professionals to be able to tell when vibration more, and can be used to test a wide variety of +27 10 595 1821, sales@comtest.co.za,
is normal and when vibration signals a need mechanical equipment, including motors, fans, www.comtest.co.za

www.instrumentation.co.za February 2019 65

 CONTROL VALVES & ACTUATORS

First Metso valves with 3D printed parts

Metso’s Helsinki plant has delivered the first
valves with 3D printed parts. The units include
3D printed metal components that allow them to
perform in a particularly demanding application,
where they need to withstand numerous fast
open-close cycles without maintenance.
“We are at the forefront of using 3D
printing in valve applications, having already
started testing the suitability of the technology
for metal components years ago,” says director
of technology development, Jukka Borgman.
“We have defined and prototyped several
concepts where the 3D printed components
can provide new levels of valve performance
compared to components manufactured with
traditional methods.”
“The beauty of 3D printing is that it allows
the customer to have devices whose new
properties can only be implemented using
the 3D printing method,” adds Jani Puroranta,
Metso’s chief digital officer. “With certain
products, another key benefit for the customer
can be exceptionally quick delivery times.”
The 3D printed parts and related
methodological investigations are part of
a broader digitalisation project at Metso. In
addition to valve component production,
Metso is already using 3D printing to additively
manufacture tools used to make minerals
consumables parts.
See how the components were printed at
https://tinyurl.com/ydc577rq
For more information contact Metso South
Africa, +27 31 502 9350, steve.clark@metso.com,
www.metso.com

Intelligent valve sensor

The intelligent valve sensor for pneumatic quarter-turn actuators
from ifm electronic features 360° position monitoring to allow precise
and continuous scrutiny of the valve condition. Problems such as
wear or dogging are reliably detected and directly communicated to
the user. This data supports maintenance planning and can also avoid
production losses. Thanks to the integrated IO-Link communication
interface and in combination with ifm IO-Link masters, the sensor can be
networked via different bus systems, allowing connection to the
ERP system.

Flexible configuration and diagnostics

The smart valve sensor matches settings to the application software (LR
Device) or inductive teach button. Any end position of the valve and the
size of the sensing range can be set. A third switch point can be selected,
for example for three-way valves or for switching off the pump to avoid
pressure peaks.
The IO-Link communication interface allows the identification
of different wear conditions. On the one hand, the sensor features
seal monitoring indicating a change of the closed position, which
can point to deposits or wear of the seal, for example. On the other,
the different positions can be counted and the time taken can be
measured.
For more information contact ifm electronic SA, 086 143 6772,
info.za@ifm.com, www.ifm.com

66 February 2019 www.instrumentation.co.za

Your valves are talking to you.
Are you listening?
Because details matter.

It’s not easy to keep every control valve and every instrument
in your plant at it’s peak performance. Even a small problem
in any one of them could result in major issues for
the entire system.

Metso’s 24/7 Expertune PlantTriage Services focus on the

details that improve reliability, safety and quality. With 24/7
real-time metrics and diagnostics, issues are quickly identified
and prioritized. Anywhere. Anytime.

Learn more at metso.com/valves

#detailsmatter
 CONTROL VALVES & ACTUATORS

Richter’s PFA-lined ball valves

Richter, a leading supplier of PFA-lined pump and valve solutions, has
a new size control ball for its KNR and KNAR valve series. Increasing
production quantities in the chemical and petrochemical industries
require larger diameter pipelines, which mean bigger valves are also
needed.
In today’s plants, everything is optimised for maximum possible
capacity and best economic results. Richter anticipated these changing
requirements with the launch of its largest PFA-lined control ball for the
KNR/F DN200 and the KNAR/F 205 mm valves. The optimisation of flow
behaviour supported by CFD (computational fluid dynamics) ensures
maximum stable flow with minimum pressure losses. The geometric
shape ensures low turbulence through the flow range and control
characteristics with true equal percentage curves at flow rates up to a KV
of 1000 m³/h (CV = 1156 gpm). Other features include:
• Universal chemical resistant PFA lining.
• Permeation and vacuum resistant construction.
• Higher efficiency due to better control behaviour especially in the
lower range.
• Lower operating costs through increased capacity.
Richter’s proven KNR design with play-free one-piece ball shaft, leak-
free labyrinth seal and maintenance-free stem sealing ensures a long For more information contact Desmond Delport, Valve & Automation,
operating life and maximum safety. +27 11 397 2833, sales@valve.co.za, www.valve.co.za

68 February 2019 www.instrumentation.co.za


Schubert & Salzer
adds GS4 series
Sliding gate valves optimised for pressures
up to 160 bar.
Sliding gate control valves are handy,
compact, light and ultra-precise. They
control liquid, vaporous and gaseous
media in a fast, precise and economic
manner. The heart of all sliding gate
valves is the two slotted discs that slide
and seal against each other. The fixed
disc, which is secured in the housing
perpendicular to the direction of flow,
has a certain number of transverse slots.
The second disc, with the same slotted
arrangement, is moved vertically against
the first, thus changing the flow cross-
section. The applied pressure difference
forces the moving disc against the fixed
disc and consequently, the sliding gate
valve seals without the need for a metal
seat.
These excellent design characteristics
can also be found on the GS4 sliding
gate valve range, which is specifically
optimised for higher pressures.
Depending on the size, the GS4 range is
available in nominal pressures:
• PN 160 (ANSI 900) up to a nominal size
of DN 80.
• PN 100 (ANSI 600) up to a nominal size
of DN 150.
The operating temperature range
is from – 200 to 550°C. In addition to
stainless steel 1.4571 as the standard
body material, special alloys such as
Hastelloy, Inconel, Duplex or Super
Duplex, are optionally available.
Comparable to the GS1 to GS3 series,
the sliding gate valves of the GS4 range
are also characterised by an extremely
small and compact design complete with
a comparably low weight. The PN 100
GS4 valve with a nominal size of DN150,
including the actuator and positioned,
only weighs 200 kg. A comparable
traditional globe style valve weighs
approximately 400 kg. This weight
advantage not only reduces the required
installation space; it is also noticeable
in terms of material use and easier
handling.
As a result of the seat arrangement
which is guided perpendicular to the
CONTROL VALVES & ACTUATORS
flow, sliding gate valves from all series
only require low actuation force in
order to operate. For instance, the
sliding gate valve with a nominal size
of DN 150 only requires a diaphragm
actuator with a membrane size of
1500 cm² in order to manage a
differential pressure of 100 bar.
Compared to a traditional globe valve,
this equals only a tenth of the actuation
force.
The low actuating force is also
noticeable when dealing with extremely
low strokes of 8,8 mm with a significantly
lower compressed air requirement. In
combination with a Type 8049 digital
positioner, no compressed air is used
when in the controlled state. Due to
the lower stroke, actuating times of two
seconds are possible for a complete
stroke movement.
Two material combinations
are available for the seat set.
The moving disc can either be
manufactured from a cobalt-
chrome based hard alloy (Stellite)
or be equipped with an SFC carbon
coating (slide friction coating).
The selection of material pairing
for these sealing discs depends on
many factors. In additional to the
friction coefficient – which has an
immediate impact on the level of
the required actuation force – leak
rates, chemical resistance, suitability
for high differential pressures,
edge stability as well as a possible
cavitation operation are also decisive
parameters. Furthermore, the
desired service life and the costs
for spare parts must also be taken
into consideration. The Schubert &
Salzer Control Systems specialists are
happy to assist you in this selection.
For more information contact
Kamil Maharaj, Macsteel Fluid
Control, +27 31 581 7800,
kamil.maharaj@macfluid.co.za,
www.macsteel.co.za
 PRODUCT NEWS
Battery powered digital
temperature gauges
Kobold’s DTE series of digital temperature gauges offers
a wide range of industrial and analytical possibilities in
applications where high accuracy and clear indication
is required, and where alarm control and displayed
messaging is useful, as in controlled environments
such as hospitals and scientific laboratories. In addition,
the range also incorporates data logging, is accessible
via NFC interface with mobile devices, and is USB PC
configurable.
One of the key aspects is the mechanical case
mounting options that follows the traditional Bimetal,
Nitrogen Actuated, and Mercury (now prohibited)
mechanical gauges.
The Universal Pt100 Class A and Class 1 thermocouple
sensors offer not only accuracy and flexibility regarding
sensor options, but in the event of the sensor being
damaged in service, instead of replacing the entire
instrument, only the sensor need be replaced. The
instrument may also be reused for other applications
where a different type of sensor specification is required.
Other features include:
• 5000-point logger with USB interface.
• NFC interface for reading log, sync clock/start new log.
• Android app for transmission of data via e-mail.
• 7x32 character messages from user set message library.
• Dual alarm relays Max/Min information.
The advanced features and versatility of the DTE offers
new solutions for many applications, typically: process
and plant engineering, storage, building management
systems, water industries, food and beverage, biomass
and HVAC.
For more information contact Instrotech,
+27 10 595 1831, sales@instrotech.co.za,
www.instrotech.co.za
7070February
October www.instrumentation.co.za
2018www.instrumentation.co.za
2019
Isobus series of connectors from Amphenol
RS Components has announced
availability of a new series of Isobus
circular connectors manufactured
by Amphenol, a leading maker of
connectivity components for industrial
engineering applications.
The key application area for the Isobus
series of cable connector sockets is in
agricultural and forestry vehicles, as the
series offers a standardised connection
that meets ISO 11783-2. The standard
specifies the physical layer for twisted,
non-shielded quad-cable operating
in a 250 kbit/s serial data network for
control and communications between
agricultural or forestry tractors and
machinery and their implements,
whether these devices are mounted,
Fast optical data transmission
The Leuze DDLS 500 optical data
transceiver has a high optical transmission
rate of 100 Mbit/s. This photoelectric
sensor allows data transmission without
cabling and without interference.
Gerry Bryant, managing director of
Countapulse Controls, says that the
transceiver can transmit all common
Ethernet protocols up to distances of
120 metres, including Profinet, EtherNet IP,
EtherCAT, Ethernet TCP/IP and Ethernet UDP.
Constant monitoring and notification
of the signal level on the easy to read LED
display allows quick reaction to issues like
soiling of the lens, ensuring simplified
maintenance and diagnostics.
The modular design of the Leuze
DDLS 500 includes an integrated bubble
level for accurate installation, while the
single-hand adjustment arrangement
allows precise alignment of the data light
semi-mounted, towed or self-propelled.
A key feature of the series of nine-
pole cable-mount circular connectors
is its two size 8 power contacts for 6, 10
and 16 square millimetre wire gauge.
Offering rapid and secure assembly,
cable connector variants in the series also
include field-installable devices, as well
as over-moulded cable assemblies. Rated
for 24 V operations, the series also meets
IP67 and IP69K ratings to protect against
water and dust ingress. To complement
the series, a selection of dust caps is also
available.
For more information contact RS
Components SA, +27 11 691 9300, sales.za@
rs-components.com, www.rsonline.co.za
beam. In addition, the device projects four
laser spots along the intended light path,
aiding in the easy alignment of the device
at a distance.
For more information contact
Gerry Bryant, Countapulse Controls,
+27 11 615 7556, bryant@countapulse.co.za,
www.countapulse.co.za

Contact in to contact out over fibre optic cable
The Omniterm FCT and FCR modules
provide the ability to send a digital contact
signal up to 4 km over a single optical fibre.
When the contact on the FCT transmitter
module is closed, the relay output on
the FCR receiver is energised. LEDs are
provided to indicate the state of the input
and output contacts, and the presence of
instrument power. Applications include
safety interlock systems, critical failsafe
alarms and alarm annunciator front
ends. The system is ideal for areas of high
electrical interference and operates off a
9-30 V DC supply.
Fail Safe is a key feature of this design
and care has been taken to ensure
the highest level of reliability. The FCT
and FCR modules are suitable for SIL2
applications, forming part of Omniflex’s
extensive Omniterm range of industrial
instrumentation. Units are designed to
be DIN rail or surface mounted at an
economical 22.5 mm wide. Other benefits
include:
• Can be used with Omni16C alarm
annunciators in IEC61508 SIL
applications.
• Potential-free contact inputs.
• Form C contact output.
Graphic terminals provide enhanced
software integration
End users and OEMs are seeking HMI
solutions that simplify and streamline
visualisation, especially in larger
applications. With the new Allen-Bradley
PanelView 5510 family of graphic
terminals, companies have an HMI
solution designed to fit the needs of
large-scale applications, improve user
experience and increase performance.
“The PanelView 5510 terminal was
designed for users needing a high degree
of integration between their HMI and
controller,” said Christo Buys, business
manager control systems, Rockwell
Automation Sub-Saharan Africa. “This new
terminal is the right option for end users
and OEMs with sizeable applications.”
Display sizes on this new graphic
terminal range from 7 to 19” (18 to 48 cm)
with wide screen, touch and keypad
options. EtherNet/IP with device-level
ring and embedded switch technology
help to support network fault tolerance
and reduce downtime. On-screen
buttons and enhanced navigation help
• 10-30 V DC supply.
• A longer distance (9 km) is available as
an option using 1300 nm multi-mode
cable.
Advantages of using fibre optic
over conventional copper or coaxial
cables include high data rate and wide
bandwidth, immunity to EMI/RFI and
lightning damage and the elimination of
ground loops.
For more information contact Ian
Loudon, Omniflex Remote Monitoring
Specialists, +27 31 207 7466, sales@
omniflex.com, www.omniflex.com
to increase operator efficiency.
Using the Rockwell Software Studio
5000 View Designer application, the
PanelView 5510 HMI features Logix tag-
based alarms, a PDF viewer, a terminal
emulator, VNC remote access, and real-
time and historical trending. An upcoming
release of Studio 5000 View Designer
will include increased application limits,
multi-controller support, support for
Logix tag-based alarms and an alarm
log viewer.
The PanelView 5510 graphic terminal
is the latest addition to the PanelView
5000 HMI portfolio from Rockwell
Automation. The PanelView 5000 HMI
portfolio also includes the PanelView 5310
series and features enhanced integration
with Logix software.
For more information contact
Christo Buys, Rockwell Automation,
+27 11 654 9700,
cbuys@ra.rockwell.com,
www.rockwellautomation.co.za
PRODUCT NEWS
RS Components launches
PLCnext controller
RS Components has introduced the first programmable
logic controller to be based upon Phoenix Contact’s
PLCnext Technology open control platform. Aimed at
distributed modular control applications in industrial
automation and machine building, the new PLCnext
Control system combines the robustness and security
of a classic PLC with the openness and flexibility of IIoT
smart devices.
The first Phoenix Contact PLCnext Control device
available from RS, designated the AXC F 2152, features
a high-performance dual-core 800 MHz ARM Cortex
processor with 512 MByte of memory. Housed in a
rugged, compact 127 x 45 x 75 mm enclosure, it also
includes an OPC UA server, fieldbus manager, diagnostic
loggers, trace controllers and automatic access to
Phoenix Contact’s Proficloud solution.
Young engineers today tend to be proficient in
high-level development environments, but often lack
the PLC programming expertise of previous generations.
The PLCnext platform is an enhancement to classical
IEC 61131 compliant PLC programming that allows
developers to program using a choice of high-level
languages. Open-source software and apps can be
incorporated flexibly within the system. The real-time
performance and data consistency associated with
proprietary, device-specific PLC coding are maintained
while the limitations are avoided.
Multiple developers can work independently using
their preferred development tools with all contributions
being captured seamlessly into a single project. The result
is faster applications development than was previously
possible.
PLCnext Control is based on an embedded Linux
architecture, expanded to include real-time capability in
its core. Linux is stable, supports secure communications
and, because it runs on many different hardware
platforms, allows scaling and use of future processor
architectures.
The PLCnext Engineer software platform uses
automation modules and object-oriented programming
to provide a single optimised
user interface for all
engineering tasks, saving time
and cost on both training
and project work. Consistent
operation worldwide is assured
by IEC 61131-3 compliance,
while functional safety
programming is certified in
accordance with IEC 61508.
For more information contact
RS Components SA,
+27 11 691 9300,
sales.za@rs-components.com,
www.rsonline.co.za
www.instrumentation.co.za
www.instrumentation.co.zaOctober 20197171
2018
February
 PRODUCT NEWS
RS introduces Harting’s compact industrial Ethernet interface
RS Components has announced availability
of the Harting ix Industrial range of Ethernet
interfaces. These new devices set a higher
standard and respond to the future challenges
posed by Industry 4.0 and the IIoT. The
innovative interface is perfect for a variety of
fields and applications including machinery
and robotics, energy, automation, data
networks and transportation.
There has been recognition that device
interfaces and system cables need to be
smaller, more powerful and even more robust.
Speed sensor with IO-Link
The new range of speed sensors from ifm
electronic has the evaluation electronics
integrated into the sensor housing. This allows
for low cost and easy monitoring or rotating, as
well as linear movements with respect to over
7272February
October www.instrumentation.co.za
2018www.instrumentation.co.za
2019
Therefore, Harting has worked in conjunction
with Hirose to develop this new technology
to deliver the robust ix Industrial miniature
Ethernet interface, which has the potential to
replace the conventional RJ45 connection.
The unit takes up 70% less space than
the RJ45 and is much safer because the
two snap-in metal hooks ensure that the
receptacle and connector are more securely
connected. Data transmission is safe,
even in EMC-critical applications, due to
the continuous 360° shield design, which
and under speed. The limit at which the output
switches is set via a potentiometer or IO-Link.
As compared to its predecessors, these new
sensors feature a robust metal housing for flush
mounting.
A special version, with ATEX approval,
is available for which no additional impact
protection is required.
Operating principle and application
The integrated inductive sensor is damped
by passing cams or other metallic targets. The
evaluation unit determines the period or the
frequency (actual rotational speed) based
on the time interval between damping and
guarantees high immunity from interference.
Other features include a robust cable
attachment, high resistance to shock and
vibration, and ability to handle 5000 mating
cycles. It is also designed to provide Cat 6A
performance for 1/10-Gbit/s Ethernet and is
standardised to IEC/PAS 61076-3-124.
For more information contact RS Components
SA, +27 11 691 9300,
sales.za@rs-components.com,
www.rsonline.co.za
compares it to the set switch point. The output
is switched during the start-up delay and when
the rotational speed exceeds the set switching
value. An LED signals under speed and switch-
off of the output.
Especially in the field of conveying
technology, the compact speed sensors can be
used for various applications, for example for
monitoring belt conveyors or bucket elevators.
They are typically used to monitor under
speed, blockage or standstill.
For more information contact ifm electronic
SA, 086 143 6772, info.za@ifm.com,
www.ifm.com
quickfind february 2019

C0MPANY TELEPHONE E-MAIL WEBSITE PAGE

ABB South Africa +27 10 202 5212 leo.franken@za.abb.com www.abb.com/za 56

Accutronics +27 11 782 8728 info@accutronics.co.za www.accutronics.co.za 49
Alien Systems & Technologies +27 11 949 1157 sales@astafrica.com www.astafrica.com IFC*,60,61
ASSTech Proc. Elec. + Instr. +27 11 708 9200 info@asstech.co.za www.asstech.co.za 32,35
Beckhoff Automation +27 11 795 2898 michellem@beckhoff.com www.beckhoff.co.za OFC*,20,
21,53
BLTWorld +27 31 274 8270 ken@bltworld.com www.bltworld.com 24
Bosch Holdings +27 31 535 6192 elsworthm@boschholdings.co.za www.boschholdings.co.za 24
Comtest +27 10 595 1821 sales@comtest.co.za www.comtest.co.za 25,62,65
Countapulse Controls +27 11 615 7556 bryant@countapulse.co.za www.countapulse.co.za 59*,70
ElectroMechanica +27 11 249 5000 karenz@em.co.za www.em.co.za 46
Emerson Automation Solutions +27 11 451 3700 rob.smith@emerson.com www.emerson.com 61
Endress+Hauser +27 11 262 8000 info@za.endress.com www.za.endress.com 5,23*,26
EOH Process Automation Solutions +27 87 803 9767 contact@eoh-pas.co.za www.eoh-pas.co.za 32*
Festo 08600 FESTO (33786) kershia.beharie@festo.com www.festo.co.za 25
GHM Messtechnik SA +27 11 902 0158 info@ghm-sa.co.za www.ghm-sa.co.za 33
Helukabel +27 11 462 8752 sales@helukabel.co.za www.helukabel.co.za OBC*
ifm electronic SA 086 143 6772 info.za@ifm.com www.ifm.com 27*,66,72
Instrotech +27 10 595 1831 sales@instrotech.co.za www.instrotech.co.za 31*,70
IS³ - Industry Software, Solutions +27 11 607 8473 clarise.rautenbach@is3.co.za www.is3.co.za 22
and Support
Krohne SA +27 11 314 1391 d.rampathi@krohne.com www.za.krohne.com 33*
KSB Pumps and Valves South Africa +27 11 876 5600 annett.kriel@ksb.com www.ksb.com 47
Loadtech Load Cells +27 12 661 0830 glen@loadtech.co.za www.loadtech.co.za 51*
Macsteel Fluid Control +27 31 581 7800 kamil.maharaj@macfluid.co.za www.macsteel.co.za 69*
Metso South Africa +27 31 502 9350 steve.clark@metso.com www.metso.com 66,67*
Michael Brown Control Eng +27 82 440 7790 michael.brown@mweb.co.za www.controlloop.co.za 7*
Morton Controls 086 100 0393 sales@mortconcontrols.co.za www.mortoncontrols.co.za 29
Omniflex Remote Monitoring +27 31 207 7466 sales@omniflex.com www.omniflex.com 71
Specialists
Omron Electronics +27 11 579 2600 info.sa@eu.omron.com www.industrial.omron.co.za 38,58
Parker Hannifin SA +27 11 961 0700 lisa.debeer@parker.com www.parker.com/za 39
Pepperl+Fuchs +27 87 985 0797 info@za.pepperl-fuchs.com www.pepperl-fuchs.co.za 44
Phoenix Contact +27 11 801 8200 sbritz@phoenixcontact.co.za www.phoenixcontact.co.za 37*,52,53
R&C Instrumentation +27 11 608 1551 info@randci.co.za www.randci.co.za 63
Reed Exhibitions +27 11 549 8300 jayne.harley@reedexpoafrica.co.za www.africaautomationfair.com 5
Reed Exhibitions +27 11 549 8300 teresa.desousa@reedexpoafrica.co.za www.reedexpoafrica.co.za 9*
Rittal South Africa +27 11 609 8294 info@rittal.co.za www.rittal.co.za 45
RJ Connect +27 11 781 0777 info@rjconnect.co.za www.rjconnect.co.za 40
Rockwell Automation +27 11 654 9700 avanwyk@ra.rockwell.com www.rockwellautomation.co.za 51,54,55,71
RS Components SA +27 11 691 9300 sales.za@rs-components.com www.rsonline.co.za 37,45,70,
71,72
SA Gauge +27 31 579 2216 sales@sagauge.com www.sagauge.com 3*
Schneider Electric SA +27 11 254 6400 prisca.mashanda@ www.schneider-electric.co.za 48,63
schneider-electric.com
SICK Automation Southern Africa +27 11 472 3733 robert.descande@sickautomation.co.za www.sickautomation.co.za 30
SICK Automation Southern Africa +27 10 060 0550 mark.madeley@sickautomation.co.za www.sickautomation.co.za 28,29
Siemens Digital Factory and +27 11 652 2795 jennifer.naidoo@siemens.com www.siemens.co.za 42,43,50
Process Industries and Drives
SKF South Africa +27 11 821 3500 samantha.joubert@skf.com www.skf.com 36,64
Technews Publishing +27 31 764 0593 jane@technews.co.za www.technews.co.za 17*
Tectra Automation +27 11 971 9400 jonathan.narainsamy@tectra.co.za www.hytecgroup.co.za 56
Turck Banner +27 11 453 2468 brandon.topham@turckbanner.co.za www.turckbanner.co.za 57*,59
*denotes advertiser

Valve & Automation +27 31 579 2593 sales@valve.co.za www.valve.co.za 68*

VEGA Controls SA +27 11 795 3249 info.za@vega.com www.vega.com Bound
insert*,10
WIKA Instruments +27 11 621 0000 sales.za@wika.com www.wika.co.za 31,35*
Yokogawa SA +27 11 831 6300 eugene.podde@ao.yokogawa.com www.yokogawa.com/za 34,41*,55
Zest WEG Group Africa +27 11 723 6000 info@zestweg.com www.zestweg.com 49*

For more information on these and other suppliers please see www.ibg.co.za