Electricity + Control April 2019

FEATURES: · Control systems + automation + systems engineering · Electrical protection + safety · Flow measurement + instrumentation · Lighting · Transformers + substations

COMMENT

ON THE COVER

Energy + information – the two commodities of modern industry

W e need to think clearly about the future and how we get this econo- my out of the dumps, don’t we? And I by no means want to be negative here – it is not in my nature. But at some point we do need to recognise that leadership, espe- cially at state level, is not just about being popular; it is also about making decisive calls and recognising that not everyone will either agree with or even understand them – but they speak to structural correc- tions to ensure that we craft the future the country both needs and deserves. In this light, I vividly recall visiting a state official in Mozambique in 1996, with dull flickering lights in his office, but he was speaking with true vision of the fu- ture of their network, their grid and their energy system. Then, a few years ago, I was visiting a state official in Lusaka, in a darkened office, with eight hours per day of load shedding on the go at the time. That led me to think back to the crisis that hit South Africa when we first went through extended periods of load shed- ding – and I reflected on the fact that it was a predictable situation. In fact, I recall giving a talk which I had entitled ‘No light years ahead’ just before the crisis hit – simply because it was clear for all to see, and had been for some years. The bottom line is that we have econ- omies that are heavily reliant on energy, and mucking about with the security of that system is really not on. What this does, of course, is bring into stark relief the role of energy as a key commodity of modern industry. You know, as a reader of Electricity + Control , that this magazine focuses on the two commodities of modern industry – energy and information. It seems so ob- vious, doesn’t it, that these two commod-

ities ride well above the technologies that give meaning to them – while we note also that these technologies continue to evolve and transform. But what brings a smile to me is when I think back to the early 1990s, when it was actually quite difficult to get folk to see the critical nexus of these two things. Information had everyone convinced; but energy was just a thing that was there … or so it felt to so many people. Nowadays energy is viewed as the most important component of any pro- cess. It must be measured, managed and indeed nurtured. Back in the day, we also ran a com- prehensive series called ‘New Electricity News’ for some years, which invited our readers to reflect on energy – and the fact that it is not a sustainable resource. That it is key to the plant and that managing it was the new game that needed to be played. It is now quite evident that energy and information need to be treated with the re- spect that they deserve. For many of us, in- formation seems the easier one now. Pro- viding you can obtain plant data, you can turn that into the appropriate information. But, unlike in the past, energy is now that commodity that has most plants most concerned. Suddenly it seems that we have little real control over our energy sup- ply – bringing starkly to the fore the need to reflect on how we can secure the energy future of our plant – and our economy. Interesting times indeed.

FEATURES: · Control systems+ automation+ systems engineering · Electrical protection+ safety · Flowmeasurement+ instrumentation · Lighting · Transformers+ substations

energy + information in industry

ECApril 2019 cover.indd 1

3/28/2019 10:09:51AM

VEGAPULS 64 is the first radar level sensor for liquids that measures at a frequency of 80 GHz. (Read more on page 21).

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Online Edition

CONTENTS

Features

CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING 4 How TSN revolutionises the concept of time John Browett, General Manager, CLPA Europe

6 Condition monitoring in consumer products plants Siemens

9 Round UP

ELECTRICAL PROTECTION + SAFETY 12 Understanding the terminology in IEC 61439 Johan Basson, Managing Director, JB Switchgear Solutions

14 Round UP

FLOW MEASUREMENT + INSTRUMENTATION 18 Accurate flow measurement in dairy production Endress + Hauser

20 Round UP

6

LIGHTING 25 The growth of horticultural lighting Gregg Cocking, editor, Lighting in Design

18

TRANSFORMERS + SUBSTATIONS 28 Transformers and miniature substations to specification Leigh Darrroll , Electricity + Control

31 Round UP

12

28

Regulars

1 Comment 21 Cover article 35 Cyber security 36 Write @ the back

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How TSN revolutionises the concept of time

Time Sensitive Networking (TSN) has quickly become a catchword in industrial automation. It represents a key technology for turning the Industrial Internet of Things (IIoT) into a reality by helping industrial Ethernet to guarantee reliable and time-predictable communications. The first step to achieve this is the creation of a synchronised system. John Browett, General Manager of CLPA Europe, looks at howTSN creates synchronisation within a network and how this benefits industrial automation applications.

Take Note!

1. Time synchronisation across distributed systems allows network devices to execute the required operations in unison, at the correct time. 2. When all components share a universal clock, it is possible to determine when an event happened on a specific machine and the time interval between two events on different components on the same network … 1 2

T SN was initially developed by the Institute of Electrical and Electronics Engineers (IEEE) as a series of open technical stand- ards for audio video bridging (AVB) in professional audio-visual systems. The result is an ISO/OSI (In- ternational Organization for Standardisation/Open Systems Interconnection) Data Link - Layer 2 tech- nology regulated by IEEE 802.1 standards. By offering deterministic, real-time messaging, IEEE 802.1 quickly expanded its scope to other fields, particularly control networks within the au- tomotive and manufacturing sectors, where it is essential to ensure that time-critical cyclic data is received within determined time intervals. Device synchronisation In order to implement determinism with low bounded latency on industrial Ethernet networks, time synchronisation is a key aspect that needs to be addressed. This feature is necessary to main- tain high precision for distributed systems as it allows network devices to execute the required operations in unison, at the correct point in time and independently of where the actions should take place. In addition, when all components share a com- mon concept of time, that is, a universal clock, it is possible to perform accurate analysis to determine when an event happened on a specific machine, the time interval between two events that oc- curred on different components on the same net- work, or the relative ordering of events that took place on different devices.

In order to implement network synchronisation, TSN establishes a unique clock system via a mas- ter-slave Precision Time Protocol (PTP), as speci- fied by the IEEE 802.1AS approved standard on ’Timing and Synchronisation for Time-Sensitive Ap- plications’ and IEEE 1588 – ’Standard for a Preci- sion Clock Synchronisation Protocol for Networked Measurement and Control Systems". According to these protocols, a network clock master, known as a ‘grandmaster’, sends time information as Ether- net packets to each node, or ’time-aware system’, within the network. Some types of time messages are used to communicate time-related information that helps to synchronise clocks across the network, or to measure delays across the communications me- dium in order to reduce their impact. Additional functions are established to build a clock hierarchy and select the grandmaster as well as configure, monitor and maintain a PTP-based system. In this way, all the real-time clocks in the nodes can be synchronised to an accuracy of 1 μ s or less, which is also suitable for the most demanding mo- tion control applications whose cycle times may be as short as a few μ s. If an error occurs, it is possible to check operation logs and trace chronologically and unambiguously what events caused the issue. As a result, operators can perform error identification and recovery tasks more quickly and easily, reducing un- planned downtime and its associated costs. Conversely, in traditional Ethernet networks, there is no global clock or shared understanding of time. Each device has its own internal clock, that

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CC-Link IE TSN optimises the benefits already offered by CC-Link IE, the world’s first open gigabit indus- trial Ethernet, by improving commu- nication functions and synchronisation accuracy.

is, its own notion of time. Consequently, errors can accumulate over time, causing time drifts that take the processors out of synchronisation. More than synchronisation Reliable time synchronisation among all time- aware network devices provides the basis for all the other TSN key functions. In particular, IEEE 802.1AS provides a robust mechanism that supports IEEE 802.1Qbv – ’Enhancements for Scheduled Traffic’ standard. This defines how to schedule data traffic queues efficiently and prior- itise the on-time delivery of time-critical frames. This process relies on time-aware shapers (TASs) that check each frame’s VLAN tag priority field and assign the message to a suitable priori- ty queue, which is defined within a schedule. The transmission of data in each queue is executed during scheduled time windows, while the other queues are blocked from transmission. In this way, TAS ensures that cyclic messages are protected against interference from acyclic traffic, thus avoiding any delays or failures to de- liver time-critical messages that can interrupt an application or even the entire production process. Furthermore, communication cycle times can be optimised, as different frames with similar prior- ities can be transmitted simultaneously. As a re- sult, TASs and fixed traffic schedules overtake the traditional carrier-sense multiple access with colli- sion detection (CSMA/CD) method, used by con- ventional Ethernet, that prevented determinism. A successful TSN implementation One of the pioneering open industrial Ethernet network technologies that has recently imple- mented TSN is CC-Link IE TSN. This is a tech- nology built around ISO/OSI Layers 3 to 7 that adopts the previously described IEEE 802.1AS and IEEE 802.1Qbv Layer 2 standards.

CC-Link IE TSN optimises the benefits already offered by CC-Link IE, the world’s first open giga- bit industrial Ethernet, by improving communica- tion functions and synchronisation accuracy. For example, this innovative solution can achieve cy- cle times as low as 31,25 μs while offering trou- ble-free handling of acyclic traffic due to its gigabit bandwidth. It provides an optimum common com- munication channel for acyclic traffic and real-time control traffic, both of which will continue to in- crease as the fourth industrial revolution becomes commonplace. By choosing this technology, manufacturers can boost their competitiveness with an increasingly popular open system that supports performance, connectivity and intelligence, within open industri- al Ethernet networks. The CC-Link Partner Association (CLPA) The CLPA is an international organisation founded in 2000 dedicated to the technical development and promotion of the CC- Link family of open automation networks. The CLPA's key technology is CC-Link IE, the world's first and only open gigabit Ethernet for automation and an ideal solution for Industry 4.0 applications, due to its unmatched bandwidth. Currently the CLPA has over 3 400 member companies worldwide, with more than 1 800 certified products available from over 300 manufacturers. CC-Link is the leading open industrial automation network technology in Asia and is becoming increasingly popular in Europe and the Americas.

Reliable time synchronisation provides for scheduling data traffic queues efficiently and prioritising on- time delivery of time-critical frames.

John Browett, General Manager of CLPA Europe.

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Condition monitoring in consumer products plants Staying competitive in production requires businesses to offer the highest quality product and to discover untapped efficiencies across the production process to reduce costs. incur technical resource support burdens and may enable only partial operational transparency. Cus- tom-analytics applications can strain companies be- cause employees have to build, maintain and keep the applications relevant to the evolving process. Compounding these challenges, varying non-stand- ard communications protocols between legacy hardware and new equipment require continuous allocation of technical resources. Dependencies between core enterprise systems and the in-house analytics applications can limit the frequency with which maintenance and analytical improvements are made to fine-tune algorithms to get actionable results without significant operational costs. As an alternative to in-house platforms and ap- plications, companies can take advantage of Mind- Sphere, a cloud-based, open Internet ofThings (IoT) operating system, to keep costs low. Offered as a ‘platform as a service’ (PaaS), MindSphere enables customers to offset the costs of IT infrastructure, programming tools and analytics services as oper- ational expenses with minimal or no infrastructure

U nplanned downtime from disruptive asset failure is a constant challenge and puts pressure on profitability in the manufac- turing industry. It stems from lack of transparen- cy into machine performance required to predict and prevent failures on the factory floor or across plants. One way companies can minimise the risk of unplanned asset failure and damage is by condi- tion monitoring through digitalisation. Condition monitoring monitors a specific asset’s parameters, including alarms and notifications on key performance indicators (KPIs), for anomalies against defined control ranges to provide perfor- mance transparency and inform when assets need to be inspected. Monitoring requires accurate and continuous input data from a variety of sensors and parameters in real, or near real, time. Digitalisation is changing the industry landscape by opening the door to more advanced analytics and data collection directly from the shop floor. Cur- rently, some manufacturers perform predictive an- alytics using customised in-house applications that

Take Note!

1. Condition monitoring monitors a specific asset’s parameters for anomalies against defined control ranges to provide perfor- mance transparency. 2. As an alternative to in- house platforms and applications, companies can take advantage of a cloud-based open IoT operating system to keep costs low and benefit from established IT expertise. 1 2

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expenditure. Companies can focus on value-added activities around their core competencies rather than on IoT platform development and mainte- nance. With an end-to-end IoT solution companies can immediately collect and monitor machine data and integrate this with other enterprise systems to achieve full operational transparency. Maintenance at the right time Condition monitoring, predictive maintenance, as- set integrity management, and predictive forecast- ing are all approaches for collecting, visualising and analysing data that describes asset health. Asset performance information can be combined and shared across other departments or business units to create a more comprehensive view of production and asset performance. Plant oper- ators and maintenance groups can plan around this aggregated information to protect throughput targets by reduced downtime and look to future product quality improvements for their customers. Trend monitoring and condition checking are two ways to undertake condition monitoring.Trend mon- itoring is the continuous measurement and interpre- tation of data over time. As an example, a company could measure a specific parameter of a machine

erators and manufacturing engineers to schedule maintenance before a shutdown.

MindSphere offers an end-to-end solution, from connectivity to analytics, to address condition monitoring and support predictive maintenance.

The power of IoT data With exponential increases in device connectivity options through cloud and edge computing, col- lecting real-time data from the entire value chain has unleashed a new wave in digitalisation with the IoT. By developing infrastructure for solution platforms, consumer products have dominated the IoT space and now process industries are looking to IoT as the next evolution in asset performance management. For example, real-time data flowing from smart industrial devices paired with control system data will give companies the flexibility to engage in more powerful predictive maintenance applications that will not divert resources from core operations. Since MindSphere takes care of IoT platform development and maintenance, plant operators and engineers can focus on interpreting the input data surrounding specific asset parameters along- side process data to evaluate the full health of their machines. New intelligent IoT devices working with IoT-enabled legacy equipment can capture more

and study that trend alongside up- time to indicate when deterioration exceeds a critical rate point. Condition checking uses suitable indicators for machine condition while running to initiate regular condition checks. Combining these strategies helps to keep machines operational and make condition monitoring a more powerful solution to improve overall machine health.These operational in- sights are most useful for machines such as rotating equipment, pumps, electric motors, internal combustion engines and presses that fail at a more unpredictable rate and have the largest downtime impact. Since these machines take on higher rates of wear and tear, monitoring multi- ple specific asset parameters with predictive analytics helps plant op-

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asset parameters through increased connectivity. The future of condition monitoring will focus on ana- lysing newly available data to understand random machine failure and prevent unexpected downtime. Performance, scalability, visibility and insights MindSphere offers an end-to-end solution from con- nectivity to analytics, including various industry spe- cific applications and solutions to address condition monitoring. Its solutions are designed to remove much of the effort, time and expense of building so- phisticated features and capabilities into machines, such as turnkey analytics and fleet manager tools that come as standard with MindSphere. In-house information technology teams and developers do not need to program IoT solutions from scratch as the features and capabilities included in Mind- Sphere can be extended to meet company needs. The platform that MindSphere provides offers: • On-demand IT infrastructure that is always up-to-date and highly secure with virtually limitless scale and trouble-free maintenance, patches, updates, security and other owner- ship responsibilities. • Capital expense savings plus savings in time, effort and skills to acquire, deploy, commission and maintain needed hardware. • Flexible pay-as-you-go cost models using con- sumption-based pricing help to avoid upfront capital costs of hardware and align costs with usage − a model that can be passed on to cus- tomers as a benefit and competitive differenti- ator. • Cost-effective access to PaaS functions – such as high-performance computing – and to ‘soft- ware-as-a-service’ (SaaS) applications, such as

advanced data analytics built on MindSphere. The open standards and interfaces of Mind- Sphere give customers the flexibility to gather data and match solutions with their customers’ infrastructure, whether the equipment was manufactured by Siemens or third parties. • World-class partner ecosystem to match solu- tions with customers’ requirements. Mind- Sphere has established an extensive network of world-class partnerships with broad domain ex- pertise and the IT capabilities to provide a robust offering of IoT solutions and flexible services. Start now The trend towards digitalisation of the world’s industrial plant facilities is already in motion and companies must get started to remain profitable and competitive. Operators can connect, collect and analyse data from aging and leading infra- structures to monitor machines in a centralised location. As the current operational costs of out- dated machinery mount in terms of more frequent maintenance requirements, repairs, onsite re- placements and hard-to-find spare parts, so many of the engineering and maintenance people who possess the relevant know-how are retiring. With MindSphere and IoT data, customers can begin digital transformations to: • Deliver operational transparency with condi- tion monitoring across products, plants, sys- tems and machines. • Optimise asset usage to ensure maximum up- time and availability. • Increase maintenance efficiencies by imple- menting predictive maintenance practices. • Drive cost-effective, flexible and scalable solu- tions with no operational interruption as busi- ness needs grow. • Leverage data availability and centralised KPIs, for greater operational insight and accountability. Thanks to the global reach of the cloud, manu- facturers of all sizes can capitalise on IoT data to open doors to markets they could not previously afford to consider, including international ones. MindSphere is supported by Siemens’ domain ex- pertise, sales and professional services as well as a world-class global partner ecosystem.

Acknowledgements to Siemens for this article: www.siemens.com/mindsphere

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Entry-level embedded PC, high processing power, compact design

These integrated multi-functional I/Os can be configured for other operating modes via TwinCAT 3, enabling the option to use fast counting or processing of analogue values: - counter mode: 1 x 100 kHz digital coun- ter input, 1 x digital input as up/down counter, 2 x digital counter outputs - incremental encoder mode: 2 x digital inputs for 100 kHz encoder signal, 2 x digital encoder outputs - analogue signal mode: 2 x digital in- puts configured as analogue inputs 0…10 V, 12 bit - PWM signal mode: 2 x digital outputs configured for PWM signal. If additional electrical signal types need to be processed, the CX7000 can be ex- panded as required by adding EtherCAT Terminals or Bus Terminals to the inte- grated I/Os. Additional I/O terminals will be attached directly to the CX7000. The Embedded PC is equipped with 512 MB MicroSD flash memory (with the option to upgrade to 1, 2, 4 or 8 GB) and is suitable for operating temperatures be- tween -25 and +60 °C. An Ethernet inter-

The CX7000 Embedded PC opens up the convenience and efficiency of the Twin- CAT 3 software environment to compact controllers. This further enhances the scalability of PC-based control technology from Beckhoff Automation – ranging from mini-PLCs to many-core industrial PCs. An advanced 400 MHz processor and built-in configurable I/Os mean that the embed- ded PC delivers an optimum price/perfor- mance ratio. The CX7000 makes considerably higher processing power available in the low-cost, compact controller segment. All the advan- tages of the TwinCAT 3 software genera- tion can be used, and the compact design, with dimensions of just 49 x 100 x 72 mm, ensures optimum scalability of PC-based control for small controller applications that typically require a minimum footprint. With multi-functional I/O channels di- rectly integrated, the CX7000 offers good value for money: - 8 digital inputs, 24 V DC, 3 ms filter, type 3 - 4 digital outputs, 24V DC, 0.5 A, 1-wire technology.

face serves as the programming interface. This makes the space-saving CX7000 ide- al for use as a cost-effective, stand-alone compact controller. In the CX7080 version, peripheral devices such as displays, scan- ners or weighing systems can be connect- ed via an additional serial interface.

Enquiries: Beckhoff Automation. Tel +27 (0)11 795 2898, or email: press@beckhoff.co.za

The CX7000 Embedded PC is a high-performance cost-effective compact controller that can be used with TwinCAT 3 software.

Faster connectivity for smart factories

With three times faster processing speed and eight times more memory than previous models of the DXM controller, the new DXM700 from Turck Banner provides expanded ScriptBasic pro- gramming capabilities and faster script processing that allows for more complex solutions to solve more applications in the factory. DXM wireless controllers are designed to facilitate Ethernet connectivity and enable Industrial Internet of Things (IIoT) applica- tions. As smart factories become more prevalent, IIoT technolo- gies are in high demand to connect manufacturing assets to the internet. The DXM700 can be used for various IIoT applications such as remote monitoring, predictive maintenance, or process optimisa- tion. It is compatible with Banner sensors and Connected Data Solutions software to create complete end-to-end IIoT solutions. Another benefit with the DXM700 wireless controller is that it takes up less space on a DIN rail due to its compact 70 mm width. Despite the smaller footprint, the DXM700 still includes most of the features and the same reliable performance as the rest of the DXM series. The DXM700 also offers advanced features that provide for flexibility in communicating, logging and using the data from the factory floor. For example, the controller includes communication protocols like Modbus RTU, Modbus TCP and EtherNet/IP to en- able communication between PLCs, HMIs and other local hosts.

Alerts, alarms, or data log files can be sent via secure email so that operators do not miss important notifications. A removable SD card can be used for on-board data logging and the easy-to-follow interactive programmable user interface includes an LCD screen and LED indicators. A cellular modem (sold separately) provides cellular internet connectivity and four sourcing outputs are available on the DXM700 for local triggers. The DXM700 can be used in numerous factory automation and

IIoT applications including: - Pick-to-light assembly - Kitting or order fulfilment - Remote monitoring - Predictive maintenance. Enquiries:Turck Banner. Tel. +27 (0)11 453 2468, or email: brandon.topham@ turckbanner.co.za

The new DXM700 wireless controller provides for faster connectivity on the factory floor.

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round up CONTROL SYSTEMS + AUTOMATION + SYSTEMS ENGINEERING

RFID antennas with IO-Link which makes them suitable for a wide range of applications. They are suitable for use in identifying work piece carriers in conveyor tech- nology, as only a small amount of data needs to be transmitted. In machine tools, magazines and moulded parts can be detected via RFID and IO-Link. This reduces cycle times and supports an increase in production quantities. In automotive production, body com- ponents or engines can be compared to order numbers via RFID in order to control processing steps or check the final assembly.

ifm offers one of the largest ranges of IO-Link sensors on the market. The new RFID antennas now complete the range. The RFID antennas are designed for connection to IO-Link masters. These masters offer up to eight M12 sockets for connection of IO-Link RFID antennas. Depending on the version, the IO-Link masters have an EtherCAT, Profibus, Eth- ernet TCP/IP, EtherNet/IP or PROFINET interface for communication to the PLC. The robust design of the antennas with protection rating IP 67 and IP 69K means they can be used in harsh industrial envi- ronments. All RFID tags to HF standard ISO 15693 can be used. Enquiries: ifm electronic ZA. Tel. +27 (0)12 450 0400, or email: info.za@ifm.com

The new RFID antennas available from ifm electronic ZA provide for easy integra- tion into automation systems via IO-Link,

A large selection of RFID antennas with IO-Link is available for wide ranging applications.

Simulation software enables virtual system design

Ian McGregor, Emulate3D Global Sales and Marketing Direc- tor, says, “As a former Rockwell Automation Encompass partner, we established great working relationships with Rockwell Auto- mation and its customers. We look forward to building on those relationships under our new ownership. Rockwell Automation’s installed base and our engineering software provides a great op- portunity to better address customers’ needs in today’s rapidly changing, technologically advanced manufacturing environment.” Rockwell Automation will add Emulate3D’s technology to its digital design portfolio to deliver solutions to automotive, logis- tics, materials handling, and other industrial applications. Soft- ware will be sold as Emulate3D by Rockwell Automation, as part of Rockwell Automation’s FactoryTalk DesignSuite. Enquiries: Michelle Junius, Rockwell Automation. Tel: +27 (0) 11 654 9700 or email: mjunius@ra.rockwell.com

Rockwell Automation has acquired Emulate3D, an innovative engi- neering software developer whose products digitally simulate and emulate industrial automation systems. By using accurate simu- lation models to improve systems planning and decision-making, followed by emulation trials that test the control system before installation, Emulate3D’s software enables customers to test ma- chine and system designs virtually, before incurring manufacturing and automation costs and committing to a final design. “We are excited about the opportunities that Emulate3D’s software offers our customers,” says Fran Wlodarczyk, Rockwell Automation Senior Vice President for its architecture and software segment. “They will now have the ability to improve their time to market and operational productivity through digital machine prototyping and virtual commissioning. This also marks another investment by Rockwell Automation to bring the Connected En- terprise to life.”

Emulate3D’s software port- folio integrates automation software with a 3D CAD model, enabling cus- tomers to test machine and system designs virtually.

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Logging accurate measurements over time

measurements as well. Delta OHM already offers the HD35 series, based on RF (radio frequency) communication. In some cases, when networks are very wide or complex, or divided across more than one facility, a mix of cabled, WiFi and RF loggers can be the best solution. The HD50 series can be integrated in such hybrid networks. Jan Grobler, Managing Director of GHM Messtechnik South Africa, says, “Apart from easy-to-use web browser access and its ability to be applied as a stand-alone or linked to numerous networks with hun- dreds of loggers, the HD50 can support practically ‘any signal’: universal inputs make it possible to integrate any transmit- ter with standard output. “Additional software is available for a wide range of solutions: database locally on PC, database on local server or cloud based. We also offer optional software for CFR21 Part 11 which is used in the phar- maceutical sector. “The HD50 has a range of standard sensors (measuring °C / RH / lux / atm / CO 2 ) and the logger sends an email alarm

when a value is higher or lower than the set threshold.” Grobler notes further, “One of the most important features of the web data logger is its ability to store variables accurately. It can be used in any industry requiring meas- urements ‘over time’. It offers reliability as well as the latest available software for ac- curate measurement readings.” Enquiries: Jan Grobler,

The ongoing tightening up of regulations that impact on industries where the mon- itoring of measurements of illuminance, temperature, atmospheric pressure, hu- midity and CO 2 is critical – in the manu- facture and storage of electronics, phar- maceuticals and frozen foods, for example – is making South African industry take a new look at how accurately it monitors its process measurements. The HD50 Web Data Logger, available from Delta OHM, part of the GHM Mess- technik Group, is a measuring device that stores data in a memory that can be lo- cated locally (in the instrument), in a data- base (on a pc or server), or in the cloud. It can be used, for instance, to ensure that temperature spikes outside of accepted parameters are recorded and can be acted on immediately. The HD50 was developed for use with one logger, which can be extended to an unlimited network of loggers. Settings can be opened from a web browser, as it has a built-in webserver, and this makes it possible to monitor the actual

GHM Messtechnik South Africa. Tel. +27 (0)11 902 0158, or email: info@ghm-sa.co.za

The data logger can store data locally, or in a database, or in the cloud to provide for monitoring over time.

ELECTRICAL PROTECTION + SAFETY

Understanding the terminology in IEC 61439

By Johan Basson, Managing Director, JB Switch- gear Solutions (Pty) Limited

air does not exceed 50% at a maximum of +40°C. Higher relative humidity may be permitted at lower temperatures, for example 90% at +20°C. Moder- ate condensation, which may occasionally occur due to variations in temperature, should be kept in mind. For outdoor installations, the relative humidity may be temporarily as high as 100% at a maxi- mum temperature of +25°C. 1.1.3 Pollution degree This topic is addressed comprehensively in the second part of this tutorial. 1.1.4 Altitude The altitude of the installation site will not exceed 2 000 m. For equipment to be used at higher al- titudes, it is necessary to take into account the reduction of the dielectric strength, the switching capability of the devices and the cooling effect of the air. 1.2 Special service conditions Where any special service conditions exist, the particular requirement applicable to the special condition shall be complied with, or special agree- The IEC 61439 series of standards is appli- cable to low voltage switchgear and con- trolgear assemblies. Johan Basson looks at some of the terminologies and explains them so that the reader may gain better understanding of their meaning. Extracts from the standard itself are used exten- sively.

1. Specific service condi- tions apply to ensure the safety and efficiency of electrical assemblies in industrial applications. Take Note! 1

IEC 61439 standards are applicable to low voltage switchgear and controlgear assemblies.

T his tutorial looks at ‘service conditions’ in which electrical assemblies may be used and, in the second part, focuses on degrees of pollution considered in these service conditions.

1. Service conditions

1.1 Normal service conditions What is regarded as ‘normal’ in the standard? If components are used which are not suitable for these conditions, appropriate steps should be tak- en to ensure proper operation. 1.1.1 Ambient air temperature For indoor installations, the ambient air tempera- ture does not exceed +40°C and its average over a 24-hour period does not exceed +35°C. The lower limit of the ambient air temperature is -5°C. For outdoor installations, the ambient air tem- perature does not exceed +40°C and its average over a 24-hour period does not exceed +35°C. The lower limit of the ambient air temperature is -25°C.

1.1.2 Humidity conditions For indoor installations, the relative humidity of the

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ments shall be made between the assembly man- ufacturer and the user. The user must inform the manufacturer if such special service conditions exist. Special service conditions include, for exam- ple: 1.2.1 Values of temperatures, relative humidity and/or altitude differing from those specified in the standard. 1.2.2 Applications where variations in temper- ature and/or air pressure take place at such a speed that exceptional condensa- tion is liable to occur inside the assembly. 1.2.3 Heavy pollution of the air by dust, smoke, corrosive or radioactive particles, vapours or salt. 1.2.4 Exposure to strong electric or magnetic fields. 1.2.5 Exposure to extreme climatic conditions. 1.2.6 Attack by fungus or small creatures. 1.2.7 Installation in locations where explosion or fire risks exist. 1.2.8 Exposure to heavy vibration, shocks or seismic occurrences. 1.2.9 Installation in such a manner that the current-carrying capacity or breaking capacity is affected, for example, in equipment built into machines or re- cessed into walls. 1.2.10 Exposure to conducted and radiated dis- turbances other than electromagnetic, as covered in the standard. 1.2.11 Exceptional overvoltage or voltage fluctu- ations. 1.2.12 Excessive harmonics in the supply voltage or load current..

a reduction of the dielectric strength or surface resistivity of insulation. There are different degrees of pollution which refer to the environmental conditions for which the assembly is intended. For switching devices and components inside the enclosure the pollu- tion degree of the environmental conditions in the enclosure is applicable. So, for the purpose of evaluating clearances and creepage distance the four (4) degrees of pollution in the micro-en- vironment, as outlined below, are established. Themicro-environment (of a clearance or creep- age distance) entails the immediate environment of the insulation which particularly influences the dimensioning of the creepage distances. It is important to note that the micro-envi- ronment of the creepage distance or clearance and not the environment of the assembly it- self, or of the components, determines the ef- fect on the insulation. The micro-environment may be better or worse than the environment of the assembly or components. 2.1.1 Pollution degree 1 No pollution or only dry, non-conductive pollution occurs. The pollution has no influence. 2.1.2 Pollution degree 2 Only non-conductive pollution occurs, except that occasionally a temporary conductivity caused by condensation is to be expected. 2.1.3 Pollution degree 3 Conductive pollution occurs or dry, non-conductive pollution occurs, which is expected to become conductive due to condensation. 2.1.4 Pollution degree 4 Continuous conductivity occurs due to conductive dust, rain or other wet conditions. Pollution degree 4 is not applicable for a micro-environment inside the assembly manufactured to this standard. 2.2 Therefore, unless stated otherwise, assem- blies for industrial applications are generally for use in a pollution degree 3 environment. However, other pollution degrees may be con- sidered to apply, depending upon particular ap- plications or the micro-environment itself.

Special service conditions may include: variations on temperature, exposure to other extremes outside the normal service conditions. humidity or altitude, or

1.3 Transport, storage and installation conditions

A special agreement shall be made between the assembly manufacturer and the user if the condi- tions during transport, storage and installation, for example, temperature and humidity conditions, differ from those in the standard.

2. Pollution / pollution degree

2.1 Pollution is essentially any addition of solid, liq- uid or gaseous foreign matter that can result in

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Distribution boards for complex applications The Gewiss 68 Q-DIN range of distribution boards, avail- able from ACDC Dynamics, is the energy distribution system designed for com- mercial and industrial appli- cations. The range of boards, with 23 versions and four modular configurations, from five to 20 modules, is highly versatile with a host of items available and the options of fixed and mobile installations for industrial power take-off (interlocked or otherwise) and domestic power take-off. The distribution system

sification, the DIN rail being adjustable in height, the prearrange- ment for insertion of terminal blocks and accessories for the group assembly, all contribute to making wiring the DIN board easy. The complete system of industrial boards for energy distribu- tion and controls is available as an empty or wired version, con- forming to international standard IEC 60439. The modern design of the boards makes them suitable for a wide range of environ- ments and the ergonomic product solutions ensure a user-friend- ly assembly. The 20-module versions can house IEC 309 socket-outlets, with or without an interlock, up to 63 A, and without having to add ded- icated boards with different sizes. The space inside the boards can house a maximum of 20 DIN modules, and up to 40 modules with the additional module. The 10- 14- and 20-module versions provide for an emergency push-button to be installed in a convenient and readily identifiable position. The large ergonomic handle simplifies door manoeuvring, especially for someone wearing work gloves. The door can be fitted with a safety lock, to restrict access to the compartment. Enquiries: ACDC Dynamics.Tel. +27 (0)10 202 3300, email: info@acdc.co.za or visit: www.acdc.co.za

The Gewiss 68 Q-DIN range of distribu- tion boards includes multiple versions to suit complex industrial applications.

has been designed to make the work of installers easier.

Particular devices such as: the hinged cover opening, the thermo- plastic screws, the lack of earth connection due to the Class II clas-

Backup power solutions for business continuity

24/7/365, to ensure that it is operating at optimal capacity and to pre-empt any prob- lems. When a universal controller detects an issue, which can be anything from a mains failure to a battery failure in a UPS installation, it raises an alarm and MPT’s operators take action in line with standard operating procedures. Parsons says some energy experts predict we will face five years or more of Eskom load shedding, which means or- ganisations will need to invest in reliable backup solutions to supplement grid pow- er. “Companies tend to make these in- vestments on a horizon of five to 20 years, so it is important to buy brands from rep- utable companies that will be around to support the solutions for years to come,” he adds. “There is also an opportunity for com- panies to look at energy efficiency optimi- sation as a means to reducing operational costs and their carbon footprint. Com- panies can benefit by taking a proactive stance to the energy crisis and creating a strategy that ensures continuity and opera- tional efficiency in the longer term.” Enquiries: Master Power Technologies. Tel +27 (0)11 792 7230 or email: sales@kva.co.za

the infrastructure they have in place is not fit for purpose. Some companies have, for example, in- vested in products and solutions that are complex to maintain and operate and they don’t have the specialised skills to manage the equipment. Others have found that it is difficult to source parts for the products they have, especially if they installed them five or ten years back. “With the boom in demand for power management solutions a decade ago, the market was flooded with suppliers and products that have not endured,” says Par- sons. “The result is that some companies are now without reliable support for their solutions. “Another issue is that organisations are dealing with multiple service providers and suppliers, leading to higher costs and com- plexity.” He says organisations are starting to look for single-source providers that cov- er sales, installation, support and mainte- nance of turnkey solutions spanning UPS, generators and more. He also notes a trend towards higher levels of automation and remote monitoring. MPT runs a real-time operations centre for monitoring power-critical equipment

As South African companies seek to con- tain rising electricity costs, reduce the operational risks of load shedding and en- sure business continuity in the face of a renewed electricity crisis in South Africa, Master Power Technologies (MPT) has re- ported growing demand for secure power solutions. MPT provides high quality backup pow- er solutions for industries where uptime is critical, such as manufacturing, mining, telecommunications and data centres. Menno Parsons, CEO and power-supply expert at MPT, says, “Without a reliable electricity supply, South African organisa- tions are relooking their power manage- ment and business continuity strategies.” He says many South African compa- nies are finding that their power-up infra- structure is inadequate, with high levels of failure or downtime. They are evaluating options such as uninterruptible power sup- plies (UPSs), generator systems and other power management solutions. “Since load shedding first became part of South Africa’s vocabulary nearly 12 years ago, most large industrial companies have made significant investments in se- cure power solutions and redundant power supplies. However, many are finding that

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M12 connectors with UL listing for safe wiring

vibration and after numerous operating years with possible material fatigue in the copper wires, a constant pressure and therefore optimum, safe and unin- terrupted contact is guaranteed. Enquiries: LÜTZE Systemtechnik GmbH.Wolfram Hofelich, email: wolfram.hofelich@luetze.de or visit www.lutze.com

Automation specialist LÜTZE, based in Weinstadt, Germany, has supplemented its prefabricated M12 connectors with UL listing (cURus), now meeting safety requirements for the North American market. The LÜTZE M12 connectors with push-in technology offer a number of advantages for control cabinet, machine and plant manufacturers because they allow fast and fault-free wiring of prefab- ricated cables. The tool-free and direct connection, which does not require pre- vious opening of the contact point, guar- antees fast wiring. With the new push-in technology, the insertion forces are low, which simplifies the connection. In con- trast, the pull-out forces are higher, so all connections provide a high level of wir- ing security. Depending on the application, the M12 connectors are suitable for trans- ferring signals, data and power in vari-

ous versions. These include a straight or angled connector, with the option of shielded or unshielded versions. The an- gled version allows the cable outlet to be positioned in 45° steps compared to the pole pattern. The new connectors have the same design as the screw terminal technology and are designed for more than 100 plug cycles. The company uses a clear colour- coding system for the wires during as- sembly. All colours in the connection block are assigned for the actuator sen- sor area and for the fieldbus wiring such as CAN-Bus, Profibus, Ethernet and Profinet, according to the corresponding standards in EN 60947-5-2. This means firstly, that it is almost impossible to con- fuse the pins and, secondly, there is no need for time-consuming and error-prone recoding of the individual colour codes. A permanent spring pushes each wire back so that, even in the event of heavy

The M12 connector range now has a UL listing.

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Polymer based IR inspection windows for safety

hazard of live work by enabling hot spots to be identified through the IR windows. The retrofitting with the IR windows also allowed for more frequent inspections of energised equipment, including electri- cal equipment that had previously been considered ‘uninspectable’ due to high levels of arc flash incident energy. In ad- dition, with the windows in place, closed panel inspections did not require the high levels of personal protective equipment (PPE) mandated in NFPA 70E, thus reduc- ing maintenance time and costs. Thermal imaging was not new to the maintenance and reliability team as it had previously retrofitted some equipment with traditional, round, calcium fluoride windows. However, the transparent poly- mer IR windows, available in various large format sizes, provide for both visual and thermal inspection with fewer units need- ing to be installed.

which leads to temperature reading errors. The IRISS industrial grade IR windows meet mandatory impact and load testing requirements of UL, CSA, IEEE and IEC. With this retrofit, the bottled water company realised substantial savings in its condition monitoring programme. The quicker, safer and more frequent inspec- tions facilitated by the transparent poly- mer IR windows allow for potential prob- lems to be identified and fixed well before they turn into unexpected outages. Based on the results at the first sites, the com- pany is now implementing the IRISS IR window solutions at 29 of its sites around North America. R&C Instrumentation is the sole repre- sentative for IRISS in South Africa. Enquiries: R&C Instrumentation,Tel. +27 (0)11 608 1551, info@randci.co.za, www.randci.co.za

Riaan de Leeuw, Vice President for IT Di- vision - Anglophone Africa at Schneider Electric, says it’s important to protect our homes and businesses against sudden loss of power and power surges. “While many people turn to generators to get through load shedding, rising fuel prices mean this is expensive, and it’s not an eco-friendly way to go. However, an uninterrupted power supply (UPS) can protect homes and businesses against downtime,” he says. UPS solutions protect and save elec- tronic equipment from the impact of abrupt changes in power supply and are scalable according to different needs. “For small businesses, for example, the UPS can be scaled to support es- sential equipment at 1 000 to 3 000 or 5 000 watts. Runtime is then dependent The inspection programme The company had developed a reliability and maintenance policy, including a three to five year improvement plan and this was communicated to all employees. Having researched its options, it decided that it would implement a retrofit using the IRISS transparent, patented polymer infrared windows, as a safer method of conduct- ing standards-compliant inspections. The large format infrared polymer windows were designated for main switchgear Bus connections, main breaker connections and fused switches, to help eliminate the One of North America‘s leading bottled water companies approached IRISS for assistance in optimising its maintenance programme and asset life cycles. The main goal was to define cost-effective, consis- tent maintenance processes, adopting the technologies to support and sustain these processes across its plants throughout the USA and Canada. As part of this multisite initiative, one of IRISS‘ distributor partners, Scott Thornton of DTM Consulting Servic- es, was engaged to provide recommen- dations for placement, sizing and type of IR windows to be installed at the Ontario, Canada facility. After an initial site survey, DTM recommended the CAP-CT series in various sizes to complete this project.

UPS solutions protect equipment on additional external batteries and actual physical load. There are solutions that will allow between one and five PCs to run, with monitors and the router or switch to allow connectivity. There are also solutions to cover up to 20 PCs with monitors, the server, router or switch, and lights if connected to the DB board. This would constitute 5 000 to 20 000 watts and runtime again is depend- ent on batteries and the actual load.” According to de Leeuw, uninterrupted power supply offers guaranteed power pro- tection for connected electronics, which enables businesses to stay open and stay connected with partners and customers. “Should power be interrupted, or fluctu- ate outside safe levels, a UPS instantly pro- vides clean battery backup power and surge protection for sensitive equipment, allowing The IRISS patented polymer-based infrared windows are unaffected by envi- ronmental and mechanical stresses, even when fitted to electrical distribution equip- ment, ensuring that the temperature data collected through the window is accurate and reliable for the whole life of the instal- lation. Crystal-based IR windows, by con- trast, are fragile and hygroscopic, causing degradation of the transmission over time

The patented polymer infrared inspection win- dows facilitate safer and quicker maintenance inspections on electrical equipment.

enough time to safely power down non-es- sential devices and keep critical business operations running. It also provides battery backup power and protection for specific equipment, including mobile devices.” When selecting the right UPS solution for specific equipment needs, de Leeuw suggests that it should have an output watt capacity 20 to 25% higher than the total power drawn by the equipment to be attached. Runtime is also important, giv- ing an indication of how long a UPS will be able to power the attached equipment in the event of a power disruption. He also advises that the UPS be un- plugged periodically to check that all the attached equipment stays powered and is in good working order. Enquiries: Schneider Electric.Tel: +27 (0)11 254 6400, or visit: www.se.co/za

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