moreTurck 109 ePaper EN

moreTurck 109 ePaper EN
Issue 01
2009
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T h e M a g a z i n e f o r C u s t o m e r s o f t h e Tu rc k G ro u p
A Focus on India
Ryan Kromhout and Frank Rohn
discuss the challenges in the
Indian market
Page 12
Seeing the Light
Vision Sensor iVu with touchscreen offers user-friendly
image processing Page 24
Compact Class
Hit the Bull's Eye
RFID system guarantees precise crane positioning in the
steel and iron works Page 26
Unmatched channel density of the Interface Module
Backplane (IMB) ensures order in the control cabinet
02
EDITORIAL_ULRICH TURCK
Conscious Investments
Dear readers, these days, regardless of whether you are
an employee or an employer, you can't avoid the financial
crisis, the banking crisis, investment cutbacks, and many
other related negative news topics. This means that we
must find the right balance between the apocalyptic mood
and calculated optimism in order to position the company,
scrutinize workflows and optimize processes. We have to
do all of this under the premise of meeting your needs better than ever before.
For Turck, an important factor in a successful crisis strategy
is not only reducing spending – in areas where it seems
to make sense – but also the conscious decision to make
investments that you as our customer will benefit from now and in the
future. Whether it is a new or enhanced innovative automation solution, customer proximity on site or our attendance at the Hanover
and Achema trade shows, savings measures in these areas would
be counter-productive, in our opinion.
And that is why, even during these tough times, we will be available to answer your questions at our trade show booths in Hanover
(Hall 9, Booth H55) and in Frankfurt (Hall 10.2, Booth D3-E8). At
both trade shows, due to the cancelations of other exhibitors, we
were able to better position ourselves in order to show you the right
solutions for your individual automation needs. To give you a taste
of what awaits you, please take a look at our customer magazine
[email protected] The product innovations, feature articles, and
application examples from all over the world presented in the following pages focus deliberately on process automation. After all, the
world's largest process automation trade show, Achema, is right at
our doorstep.
Whether as a physical layer specialist in process automation or as a
forward-looking partner for factory automation, I am sure that Turck
will impress you with its expertise and competence in finding the
right solution to meet your needs.
We are looking forward to your visit!
Warmest regards
Ulrich Turck
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CONTENT_1_2009
NEWS
Innovations for the Automation Industry
04
COVERSTORY
INTERFACE MODULE BACKPLANE: Compact Class
Unmatched channel density of the IMB ensures order in the control cabinet
08
INSIDE
INDIA: “Our Network Still Stands”
P&A Editor-in-Chief, Dr. Ulla Reutner, interviews Turck's Frank Rohn and Ryan Kromhout
12
ESCHA TSL: Touch Me
Buttons and LED lights from Escha TSL are opening doors for public transportation
56
WORLDWIDE
CHINA: Three Pillars of Success
Sales, production and system integration: Turck's path to becoming the sensor leader in China
14
TREND
WIRELESS: Wireless Transparency
Turck is expanding its portfolio for the physical layer with wireless components
18
RFID IN PA: RFID in Hazardous Areas
Radio frequency identification opens up new opportunities in process engineering
22
IMAGE PROCESSING: Visionary
Vision sensor combines camera features with simple sensor operation
24
APPLICATIONS
RFID: Sensible Weightlifter
BL ident guarantees precise crane movement in an iron and steel works factory
26
RFID: Seeing through the Smoke
BL ident improves warehouse management in Chinese cigarette factories
30
SENSOR TECHNOLOGY: To the Point
FAW-Volkswagen relies on uprox+ sensors in its automobile production lines in China
32
FIELDBUS TECHNOLOGY: Minitubers at a Glance
Quantum Tubers monitors atmospheric conditions in potato propagation using BL67
36
FIELDBUS TECHNOLOGY: Cranes with Brains
BL67 modular fieldbus system works reliably in huge portal cranes from ABB
38
FIELDBUS TECHNOLOGY: Intrinsically Safe Field Communication
Tianjin Chemical Factory transfers signals from the hazardous area using excom remote I/Os
40
FIELDBUS TECHNOLOGY: Well Filtered
excom makes it possible for Evonik Degussa to receive signals in hazardous areas
44
INTERFACE TECHNOLOGY: Accelerating Reliably
Schwelm Anlagentechnik trusts its gas fuel pumps to interface technology from Turck
46
INTERFACE TECHNOLOGY: Water for Höchst
Infraserv Höchst relies on the 19-inch interface technology for water treatment
48
INTERFACE TECHNOLOGY: Black Gold – Yellow Technology
Turck measuring amplifiers ensure monitoring of oil temperatures in a Russian port
50
CONNECTION TECHNOLOGY: Flexible Production
US manufacturer Genentech relies on rugged connectivity and fieldbus solutions from Turck
54
TECHNOLOGY
BL20-HART MODULE: It is Hart
Hart-compatible I/O modules increase functionality of the BL20 fieldbus system
60
PROFIBUS DIAGNOSTICS: Bus Diagnostics
Ethernet Profibus Interface PB-XEPI with web server monitors fieldbus communication
62
BASICS: How Pressure Sensors Function
Part 5: Design, functional principles and mounting options of the most important
sensor technologies
64
SERVICE
CONTACT: The Fast Lane to Turck
We will show you how, when and where Turck is there for you
66
CONTACT: Imprint
66
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03
Factor 1: FAW-VW Automobile relies on
uprox+ sensors in Changchun in northeastern China
Page 32
Intrinsically safe: excom remote I/O ensures reliable signals at Evonik Degussa
North America
Page 44
World success: Presskey buttons from
Escha TSL open doors in countless
buses and trains
Page 56
04 N e w s _ i n n o vat i o n s
Trade Show
Booth Improved
 Despite a tense market situation
everywhere, Turck will still be attending the most important trade shows
in 2009. The trade show booths this
year will be more accessible both at
the Hannover Messe, as well as
the Achema show in Frankfurt, Germany. Turck will be exhibiting current product innovations and triedand-trusted solutions from sensor,
fieldbus, interface and connectivity
technology in Hall 9 at booth H55
in Hanover, Germany. At th Achema
trade show in Frankfurt, the physical
layer specialist will be demonstrating solutions and concepts from the
fields of “point-to-point”, “point-tobus,” and “bus-to-bus” in Hall 10.2
at booth D3-E8.
New Office
in Turkey
 Turck is continuing its successful expansion strategy with a new
sales office in Turkey. The Turck office
in Istanbul is managed by automation specialist Onur Celik. The
34-year-old studied electrical engineering at the university in Istanbul
and afterwards began working for a
well-known manufacturer in the automation industry.
As a location for
the Turck office,
the company has
selected the Asian
district of Istanbul
because there is a
major industrial area
there and that is where the most of
the major Turkish automobile industry players are located. Above all,
Celik is currently opening the doors
to numerous projects with the innovative BL ident RFID system.
2-Wire Sensors
 Turck has developed a new inductive sensor in a cuboid
form that is especially designed to meet the specifications of the
French Committee for Standardization of Production and Equipping
(CNOMO). Equipped with a separate bracket, the flush-mounted
Bi10-QN26 permits the active surface of the sensor to be positioned
in four directions. This means the new sensor is suited for numerous
automotive applications, especially for French automobile manufacturers Citroen, Peugeot and Renault. The bandwidth ranges from
the positioning query on the conveyor belts to parts checking in
assembly processes. The cuboid-shaped sensor (height: 26 mm) in
unpoled 2-wire design
has a rated switching
distance of 10 mm and
is designed for operating voltages of 10 to 65
VDC. The IP67 sensor
displays the swiching
distance by means of
a luminous LED and
thus facilitates simple
function control directly
on site. The new Bi10QN26 is available as an
M12 pigtail variant with
cable lengths of 0.8 and
0.15 meters, as well as
non-ready-made cable
variants (2 m).
Single Segment
Backplane for DPC
 The Diagnostic Power Conditioner System (DPC) has
been expanded with the addition of a new module rack (backplane) for individual FOUNDATION fieldbus segments. After
Turck recently introduced new backplanes for power supply
and diagnostic of up to four H1 segments, the company is now
introducing a module rack in the form of the DPC-49-1RMB,
especially for smaller bus architectures. Like the module
rack of the DPC-49-4RMB product line, the new
single segment backplane has a redundant power
supply, as well as a relay alarm contact for simple
diagnostic analysis. Based on the established FF
energy supply module DPC-49-IPS1, only one H1
segment, however, is selectively supplied redundantly via the module rack. The connections to the host
system and the field level are made via 3-pin removable screw terminals. A shield bus or a screw clamp
that is internally connected using the M5 thread bolt
ensures high electromagnetic compatibility (EMC)
and equipotential bonding.
05
85th Birthday
 Hans Turck, one of the founders
of the Germany-based sensor, fieldbus, connectivity and interface specialist celebrated his 85th birthday
on January 9, 2009. After completing his engineering degree in 1950,
the celebratee gained work experience in the electronics industry for
ten years before he started his own
engineering company in Muelheim,
Germany. In 1965, Hans Turck sold
his first product, an amplifier that his
brother Werner produced in Halver,
Vision Sensor with
Touchscreen
 High-performance image processing technology does not necessarily have to be
expensive or difficult to handle. As proof of this, the automation specialist, Turck, will
introduce its iVu vision sensor at the Hannover Messe. This is the first image processing system with an integrated touchscreen. This compact solution unites the sensor's easy handling with camera functionality, and, thanks to its compact housing and
free software and firmware updates, it is considerably more attractive pricewise than
classic image processing solutions. The Vision sensor was developed by Turck's optic
partner Banner and is perfectly suited for a multitude of different detection tasks that
once required time-consuming parameterizing via computer software – from code
detection in the pharmaceutical industry to label inspection and content checks in the
chemical and food industry. Due to its intuitive operation via the touchscreen, even
inexperienced first-time users can install and learn to use the Vision sensor quickly for
more on page 24 

immediate operation.
Hart Modules for BL20
 Turck is offering new analog electronic modules for the BL20 remote
I/O System, which is authorized for use in Atex Zone 2. The dual-channel
I/O cards are Hart-compatible and facilitate the expansion of digital fieldbus
communication by using existing 4 to 20 mA wiring. The Hart modules that
were premiered at the Hannover Messe allow users to easily connect their
analog field devices to the process
control system via the universal bus
terminal system and embed them in
a consistent asset management concept based on FDT/DTM technology.
With the addition of analog electronic
modules to its fieldbus system, Turck
is responding to the huge demand for
efficient I/O solutions for almost all fields
in processing technology. The Hartcompatible modules facilitate the interruption-free transmission of additional
measured values or diagnostic data
from the field via the modulated digital
more on page 60 

signal.
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1/2009
Sauerland. In 1998, Hans Turck
handed the reins of the company
over to his son Ulrich. Today, he is
enjoying retirement together with
his wife; both are in good health,
and they split their time between
Mülheim and their second home in
South Africa.
Street Car with
Turck Sensors
 Since March 2009, a street car has
been in operation in Dresden that is
transporting not only passengers,
but also, for the first time, delivering
measured data from serial operation.
In addition to Dresden's bus companies and the automobile manufacturer Bombardier, Dresden Project
manager, Prof. Michael Beitelschmidt
from the Technical University in TU
Dresden, was able to obtain other
well-known companies as partners.
For the trade show street car, Turck
has made ultrasound sensors available that log data on the bogies.
06 N ew s _ i n n o vat i o n s
Dual Sensors for
Manual Valves
 Thanks to new stainless steel
mounting brackets, Turck customers can now use the double sensor
on hand-operated valves for easily
transmitting a valve's position. The
bracket is easily mounted on the
valve with two screws and attached
to the manual lever by a threaded
bolt. The distances between the
holes meet conventional standards
so that the bracket can be used on
most valves.
Secure in Hazardous Areas
 At the Achema show being held
this year, Turck is launching a range
of new solutions for use in hazardous areas. Besides the RFID tags
that can be used in Zone 1, the
Namur sensor product line will be
the main attraction. All inductive,
capacitative, and magnetic field
sensors with a standard Namur
output are now approved for Dust
Zone 20 and Gas Zone 1 – many
even up to Zone 0. All sensors mentioned are additionally approved for
use in safety-related applications
up to SIL2, in accordance with IEC
61508. Moreover, Turck is now
offering sensors with the innovative
TC terminal chamber concept and
expanded temperature range (-40 to
100 °C) in the IP68/IP69K protection
class. The customer can therefore
find the right sensor for any application and can dispense with expensive special variants. Lastly, Turck
has the appropriate intrinsically-safe
interface devices in its product line
for any sensor.
Interface Module
Backplane
 At the Achema trade show, Turck will be presenting a rugged Interface
Module Backplane (IMB) that combines installation space for up to 32 I/O
channels with standardized system connections and a redundant power supply (24 VDC). Digital I/O modules as well as Hart-compatible analog cards and
DTM configu rable temperature amplifiers complete the new point-to-point
solution and integrate it into a consistent asset management system. Thanks
to the lower channel price compared to DIN rail interfaces, the IMB is the ideal
solution for highly expanded control
cabinets with several hundred inputs
and outputs as well as for simple applications with few I/Os. The
Backplane offers space
for up to eight interface
modules on a compact
basic footprint of only 175

x 210 mm. more on page 08 
Correct Torque
without Tool
 Turck's new M12Nm connector is the first plug-in connector worldwide that can be manually tightened without the aid of a
torque wrench and with a defined torque. The integrated torque
check ensures that the plug-in connection is tight in accordance
with the IP67 protection class. The plug-in connector was developed by wiring and connection technology specialist Escha. The
M12Nm functions similar to a gas cap: The user first positions the
connector inside the coupling
via an axial movement. Then,
he or she manually tightens
the lock bush made of plastic. When the defined torque
is reached, the lock bush
disengages. The user gets
clear haptic and acoustic
feedback and knows that
the connection is tight at
this moment and that additional compression is prevented. The male and female
M12Nm connectors will be
available in the second quarter as 3, 4, and 5 pin versions as as well
as in straight and angled designs.
07
Sensor Application Award
Wireless Components
for the Physical Layer
 Turck is expanding its portfolio for the physical layer by adding versatile gateways
and node points for wireless data transmission. The new wireless product line supports a multitude of signals: from analog data concerning binary contacts and frequency signals, to digital protocols via RS232 and RS485. To be able to transmit all
data from a remote I/O station wirelessly reduces wiring costs for users and makes
the supply chain more efficient. Depending on the application, the customer has the
choice between a cost-effective point-to-point solution – a gateway with one node –
or a network architecture in which one gateway can operate up to 99 nodes. To implement simple retroactive measurements or data transmissions, the single version is
ideal, as it can transmit up to eight binary inputs and four binary outputs or four analog
signals. More complex automation tasks can be implemented via the wireless network
more on page 18 

architecture using RS232 or RS485.
Ethernet Profibus
Interface with Webserver
 Turck is now offering the Ethernet Profibus PB-XEPI coupler with a
diagnostic function and integrated webserver. The diagnostic unit allows
users to continuously monitor, for the first time, a large number of Profibus
networks in parallel during ongoing operation and makes remote maintenance over the internet possible. The interfaces are simply integrated
into the Profibus networks to be monitored, and establish a communications and diagnostic infrastructure via the Ethernet protocol,
thus allow ing remote maintenance for all integrated fieldbus networks via a computer
web browser. The PB-XEPI can
be configured as a pure listener without its own Profibus
address or as an active network
more on page 62 

subscriber.
 In November 2008, the most
innovative sensor applications were
awarded the German Sensor Application Award at the SPS/IPC/Drives
trade show. The award is an initiative from Turck, the Ruhr University
of Bochum and the Konradin trade
publications electro Automation and
KEM. The winners, Philippe Huysentruyt (Recticel Automobilsysteme), Herbert Stock (Cavitator
Systems) and Ludwig Wenninger
(Clariant), celebrated with jury members Uwe Sticher (Daimler) and
Werner Turck (from left to right).
Multifunctional
Signal Lights
 With the EZ Light Series TL50,
Turck is launching a versatile and
easy-to-install multifunction signal
light. Depending on the individual
application, users can chose between
versions with up
to five signal lights
(without alarm
sound) and versions with up to
four signal lights
and an integrated alarm sound
device (maximum volume 95
dB). In both versions, pre-assembled,
long-lasting LED elements ensure
clearly visible system status displays –
whether they are mounted on the
machine, in the control cabinet or at
monitored locations within the production line. The signal lights were
developed by Turck's optic partner
Banner.
 Webcode

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more20910e
8 C O v E r S T O r y _ i n t e r fa c e
module backplane
Author
ryan Kromhout
is the director of
product management
process automation
at Turck Germany
in Mülheim
Webcode | more20900e
In addition to analog
I/O cards, four-channel
digital modules are
available for the IMB
Compact Class
Unmatched channel density of the Interface Module Backplane (IMB)
ensures order in the control cabinet
9
N
 Quick read
The new Interface Module Backplane combines small space with
high channel density – up to 32 I/O channels – with galvanic separation and redundant power supply, thereby creating space in the
control cabinet. Hart-compatible analog cards and DTM-configurable temperature amplifier complete the new I/O solution and facilitate consistent asset management concepts for the physical layer.
S
eparating, remodeling, adapting, and processing – the tasks in the physical layer,
which is the interface between field devices and the process control system, are just as versatile as the interface solutions used. regardless of
whether in the expansion housing for the DIN rails,
as a Europe card for the 19-inch racks or as IMC
cartridges in IP67 construction, two features are
influencing the decision in favor of interface technology more strongly than ever: The space required in
the control cabinet and the total costs per channel.
With the new Interface Module Backplane (IMB),
Turck is now expanding its comprehensive portfolio
with the addition of a rugged and extremely compact I/O solution for the physical layer. In a compact
footprint of only 175 x 210 mm, the new module
racks, which Turck will be introducing at Achema,
offer space for up to eight interface modules – and,
depending on the customer's needs, up to 32 digital inputs/outputs or up to 16 analog I/O channels.
Users are therefore able to install control cabinets
with an enormous channel density of up to 1,152
input/outputs.
The new module racks have more on the box
than pure interface shafts: Using standardized analog and digital system couplings for the most common process system manufacturers, redundant voltage supply and high temperature resistance, IMBs
provide a new level of flexibility in the control cabinet.
Thanks to their lower channel price compared to DIN
rail installations, the easy-to-handle IMB point-topoint solution is ideal both for fully expanded control
cabinets with several hundred inputs and outputs, as
well as for simple applications with only a few I/Os.
Minimal engineering expenditure
The highlight of the station: Because the Backplane
unites the complete connection level, and the I/O
channels can be galvanically separated simply by
inserting the interface cards, the engineering time
and effort is reduced enormously for the entire interface level – both in the case of maintenance, as well
as scheduled expansions. The easily accessible,
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1_2009
10 C o v e r sto r y _ i n t e r fa c e
module backplane
intrinsically-safe screw or spring terminal connections, as well as the system connections separated
by color or space, prevent connection errors effectively and offer “hot swap” functionality for the control cabinet.
Because the pin assignment for the system
connections is adapted directly to the respective
process control system, users can dispense with
special connection modules and, instead, use readymade, cost-effective, and highly available 1:1 cables
– a considerable advantage with regard to the supply
of the electronic components used, as well as the
installation and maintenance costs of the interface
level.
Safety on board
The Backplane is a purely passive component as a
shunting level of the entire I/O solution. In contrast to
similar systems, there is no active component on the
hardware that would be able to bring the entire parting plane to a stop in case of an outage. Since each
individual interface card is secured, the availability
of the parting plane is ensured in case of individual
channel outages.
Thanks to the IMBs, Turck is additionally including a simple redundancy concept for the connection
level to the process control system. In traditional
point-to-point wiring, interrupted connections were
able to be compensated for only by an artificial doubling of the input-side signals, however, the redundant connections for the I/O cards in the process
control systems now facilitate separate safety concepts for electronics and wiring.
The energy expended in the entire plant plays
an increasingly important role for plant operators.
Ultimately, the efficiency of a process rises and falls
in relation to its total cost of ownership – which the
energy balance produced by 4 to 20 mA transmitters
can make a considerable contribution. In this case,
the Turck developers have achieved a reduction in
energy consumption for the transmitter menus (AIA)
without impairing transmitter performance. Even the
loop-fed analog input/output cards are working with
enormous efficiency.
Asset Management enabled
According to its claim of not just providing products
but rather comprehensive automation solutions,
Turck also relies on consistent asset management
strategies with its new interface module rack: Both
dual-channel analog input/output interfaces, as well
as the available transducer/isolating amplifiers, are
Hart-compatible and facilitate the transmission of
additional measurement and diagnostic data via the
modulated digital signal. Based on proprietary device
drivers – DTMs for short – users can parameterize
the temperature amplifiers used in this way.
They can also configure the field instrumentation
underneath the parting plane with the aid of a single
manufacturer-independent engineering tool, like the
cost-free project planning software, PACTware. The
parameterizing tool can be used to easily manage
DTMs independent from the bus protocol, visualize
features and settings in different basic applications
(frames), and parameterize the connected device to
be user-friendly in just a few mouse clicks.
Above and beyond remote maintenance and
central asset management, the interface cards for
the new Interface Module Backplane also come
with diagnostic LEDs for monitoring the respective
operating statuses. Up to two colored LEDs (digital
input/output cards) display the switching statuses
of the monitored outputs in yellow. In case of an
error in the input circuits – for actuated input circuit monitoring – the corresponding LED changes
to red whereupon the relevant output relay and the
alarm relay signal are de-energized. Thus, the Backplane interfaces make possible the simple function
control of the I/O level directly on site in the control
cabinet.
11
The comprehensive Turck interface product line offers the right design for any application, from cartridges to
DIN rails to the 19-inch card and the brand new Interface Module Backplane
High temperature specification
Like the DIN rail interface devices, the Backplane
interfaces stand out due to their high temperature
specification. With an operating temperature range
of -20 to +70 °C, the assembled Backplanes are
suitable for installation in non-climate-controlled cabinets or in control cabinets that are heavily impacted
by warm air circulation.
The design of the passive Backplane ensures
efficient heat dissipation – regardless of whether the
new point-to-point solution is set up horizontally or
vertically. This is one benefit that not only increases
flexibility in dealing with the interface solution, but
also raises its average working life between outag-
es (MTBF), and thereby its reliability as well as the
capacity of all connected field devices.
Summary
With the new Interface Module Backplane and the
appropriate two and four channel interface cards for
up to 32 digital or 16 analog I/O channels, Turck provides a channel density in the control cabinet that is
not feasible with DIN rail interfaces. Particularly in highly automated processing plants with several thousand
I/O channels, the compact interface stations offer a
major advantage. Integrated into a consistent asset
management concept, the Interface Module Backplanes pay off even for smaller connectivity solutions. N
Primarily for
installations with
a high channel
density, the
IMB is a true
alternative to
classic interface
solutions
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12 I N S I D E _ I N D I A
Ryan Kromhout (l.) and
Frank Rohn summarize
their first three years in
India in a positive light
„
“
Our Network Still Stands
P&A editor-in-chief, Dr. Ulla Reutner, speaks with Frank Rohn, director sales process automation,
and Ryan Kromhout, director product management process automation, about Turck in India
Mr. Kromhout, Turck has had an
affiliated subsidiary in India for
three years now. How do you meet
the special needs of this market?
Kromhout: We constantly exchange
ideas with our managing director in India,
Anuj Nijhawan, who has a lot of experience in process automation. These
exchanges have taught us a lot about the
Indian market, which has many unique
features that we meet in our product
portfolio. In these three years, the projects that we have completed have also
shown us where we still have improvements to make.
Mr. Rohn, you are responsible for
sales in Asia, among other countries. What meaning does India
have for you?
Rohn: I travel often to India because
this market is very important. Our team in
India is especially knowledgeable when it
comes to process automation. All of our
employees in India have a lot of experience in the process automation sector
so we are rapidly advancing in this field.
However, in factory automation, we had a
lot more pioneering work to do. For most
countries that we do business in, it is the
other way around.
Where in Asia does Turck do business besides India?
Rohn: We established our own company in China several years ago and initially focused on factory automation. In
2005, we also began to focus on process
automation there. At that time, we founded a subsidiary in Singapore, which rep-
resented our process automation kick-off
in Southeast Asia. We have also had a
sales office in Bahrain in the Middle East
since 2007.
Many other process automation
suppliers have been doing business in India longer than Turck.
How do you plan to catch up?
Rohn: That is the bane of all medium-sized companies. You cannot enter
every single market at the same time.
With a workforce of 2800, we do business in 27 countries; we entered the US
and Chinese markets early on and are
the market leader in certain fields in both
countries. This naturally ties up capacities. To get a foot in the door in India,
despite our late start, we have had to
operate more efficiently than other com-
13
panies who have a longer history. We
have succeeded in recruiting professionals in process automation for all regions,
in Singapore, the Middle East, India and
China. It is also important to adapt products to meet Asian market needs – a
process which represents a huge hurdle
for many European suppliers.
You once said that a “special price”
is required in India. How can a premium product supplier like Turck
guarantee this?
Kromhout: Certainly not with the
present product portfolio. In India, for
example, point-to-point wiring is used
much more widely than in the European
or American markets. We accomplish this
with products from the interface product
line that we design as efficiently as possible in order to offer them at a competitive
price as part of project business. Of course,
we must not neglect the requirements of
our major customers. All of our technical and production know-how flows into
development. We are and remain a supplier of premium products, even in India.
This is certainly not so easy given
the pressure on prices described.
Rohn: It is difficult, but possible. The
demands of Indian engineers on quality are very high. Only those companies
that walk the tightrope between reasonable pricing and excellent quality will
survive. Our sales network in India is
still standing, no project passes us by,
and every large company has gotten to
know Turck in the meantime. And we will
continue working on adapting our product portfolio to meet the specific market
requirements.
How do you manage to price your
products competitively and yet
maintain such a high quality?
Kromhout: With our IME interface
module, for example, we have placed a
high priority on efficiency. We have dispensed with certain features, such as the
removable terminal block, and we have
optimized housing, as well as printed
circuit boards, so that we can work with
components on one side. This allows us
to achieve cost savings without having to
compromise quality.
Rohn: Our successes in the process
automation sector in India are based on
excellent service. The training of our people on site, all highly qualified technicians,
is very good. You can't afford inadequate
technical support in India.
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So, it isn’t the quality and product
price alone that pave the way for
Turck in the Indian market?
Kromhout: No, on the contrary,
especially since there are also products
where direct price comparisons are not
an issue. This is seen, for example, in
new developments, like our backplane
interface module that is characterized by
a high channel density, high temperature
consistency, and standard redundancy.
It opens the user up to considerable
savings options in the control cabinet.
If you take a machine with 2,000 I/Os
as a basis, these backplanes allow you
to dispense with two to three control
cabinets.
Does the Indian process automation industry use the total cost of
ownership as a basis for their
investment decisions?
Kromhout: Total cost considerations work as incentives for a new kind
of automation, that is before the specifications are written because they can
no longer be changed in the engineering
phase. This applies not only to the backplane example. But we also begin discussing our fieldbus product line early on
in the project phase. We show how our
power conditioners make operating the
technology more intuitive, thus making
it easier to interpret the diagnostic data.
This reduces the resistance in India to
use fieldbuses.
Rohn: However, those who try to introduce the European-American concept of
TCO to the Indian market will fail. First
of all, we European manufacturers have
to learn to listen to customers because
they have a very deep understanding of
TCO. The Indian version is a much more
pragmatic approach than is common
in Europe. We can learn a lot from this,
particularly from discussions with EIL,
Engineers India Limited. This company
has helped us develop our products,
particularly with a view toward the long
term.
What meaning does EIL have for
you?
Rohn: EIL, and of course the Reliance Group, India's largest private sector enterprise, as well, continue to gain
in influence, even among control system
suppliers. In India, it has been a while
since European and American corporations such as Shell and Chevron
have been able to dictate technological
trends. 
“
For the Indian market, we are
focusing on the efficient design
of products in order to be able to
offer them at competitive prices –
without sacrificing quality.
”
Ryan Kromhout
“
Users in India have a very deep
understanding for Total Cost of
Ownership. But the Indian version is
a much more pragmatic approach
than is common in Europe.
”
Frank Rohn
Author
Dr. Ulla Reutner is
editor-in-chief of the
trade magazine P&A
www.pua24.net
Webcode | more20930e
14 W o R L D W I D E _ C h i n a
N
 Quick read
Almost 15 years after entering the market in the middle of a stormy
growth phase in the Chinese economy, Turck Tianjin is one of the
most successful and advanced companies in the development zone
in the Northern Pacific. The market leader in sensor technology is
also benefiting from direct sales and customer-oriented support in the
most heavily populated country in the world.
C
hina's growth engine continues to steam
ahead. Despite the financial crisis and
rate of price increases, China remains
a serious economic power house in international
markets. As the third largest economy, the third
largest trade nation, and, owning the largest foreign
exchange reserve with over $ 1.53 billion worldwide,
the People's Republic of China has become a solid
player in the world economy in the thirty years since
Mao's Cultural Revolution. Along with Japan, China
has become a decisive economic force in the Asia
Pacific Rim. In numerous manufacturing industries
and production, China has long surpassed all other
nations as the world's largest producer – whether in
the iron or steel industry, in pit coal transport or in
farming and agriculture.
The growth potential of the Chinese economy
has long since been discovered by foreign companies. Alone in the first six months of 2008, many
companies, including some of the largest corporations in the world, ploughed about $ 54 billion into
the economy of the People's Republic. In addition to
the United States, China has become a very attractive destination for direct investments.
Market entry in the reform phase
The economic situation in China looked a lot different in 1995. When the founders of Turck decided
to become the first foreign supplier of automation
solutions to invest in a production and sales location in China, the economy there was in the middle
of a reform and high growth phase. At this time, the
Chinese economy was characterized by enormous
Author
Shuxiang Liu is the
Vice President of
Marketing at Turck
China in Tianjin
Webcode | more20940e
Turck employs more
than 450 employees in
production, marketing,
and sales in China
Three Pillars of Success
Nationwide sales, local production, and individual system integration are the pillars
along Turck's path to becoming the market leader in sensor technology in China
15
Turck is represented by a sales,
production and
system integration
company in China
more @
1_2009
16 W o rldwide _ C h i n a
At trade shows,
Turck China introduces itself to its
customers on site
“
In the past 14
years, we have
always quickly
responded to the
needs of our customers. We were able to
offer a service that
would satisfy our customers throughout
the country.
”
Xiaowei Peng,
Vice President of Sales,
at Turck China
growth in the gross national product, on the one
hand, and, on the other, by an even higher rate of
inflation. In no way could you call it a gold rush when
the family company founded Turck Tianjin Sensor
Co. Ltd., the first location in the strategically important Asian economic area.
At this time, the Technological Development
Area (Teda) had already been well established for ten
years in the eastern part of the city of Tianjin and
offered Turck, both politically and geographically, the
ideal location for the planned step of offering customers in China automation solutions and support
directly on site. The city has a sea port and an airport
both of which are located close to Beijing, as well as
connections to eight highways leading to the northern, northeastern and eastern regions of China. As a
business and development center, the coastal region
was and is subsidized by the government.
Efficient direct sales
Right from the start, Turck Tianjin relied on direct
sales of the innovative sensor, interface, and connection solutions through its own sales specialists.
In direct meetings with Asian customers, not only
were automation solutions introduced, but the distinct corporate culture and strong image of the Turck
brand were also conveyed. By 1997 Turck Tianjin
had already supplied 1,000 customers – commitment, sense of responsibility and the strong belief
in one's own products led to the establishment of
the Turck brand as the “yellow cyclone” among the
trade press and customers. After fieldbus solutions
were first offered in 1999 and implemented at the
production facility of the FAW Volkswagen Group,
for example, sales from the Chinese subsidiary broke
the 100 billion Yuan mark (the equivalent of 11 million
Euro) in 2000.
As in Germany, where the sales divisions are
separate from the corporate headquarters, sales
offices in China are divided into defined regions and
industries. The advantage of this sales structure:
Based on clear responsibilities, a dense sales network is emerging in which the sales employees are
able to care for their specific customers effectively
and individually – even for the long term. With this
sales organization, Turck Tianjin has so far been able
to realize annual sales increases of more than 40
million Euro. “In the past 14 years, we have always
been able to react quickly to the needs of our customers,” explained Xiaowei Peng, Vice President of
Sales at Turck Tianjin. “We were able to offer a service that would satisfy our customers throughout the
country.”
Renewed growth
In order to be able to advance the company's successful establishment in the Asian market more
intensely, facilitate broader business and cooperation
models and reach even more customers with innovative products and total solutions from Turck, the
company founded the production subsidiary Turck
Tianjin Technology Corporation (TTT) and Turck
17
Automation Systems Corporation (TAS), which functions as a system integrator, in 2004. While employees from the production subsidiary Turck Tianjin
Technology Co. are primarily responsible for the
production of components for the Asian market, the
system integrators of Turck Automation Systems Co.
plan and handle the implementation of automation
solutions in individual plant concepts based on customer needs and applications. For an equally comprehensive; as well as an integrative business model,
the Chinese subsidiaries were honored by the city of
Tianjin as the “best company with foreign investors”
(2004/2005) and as the “most advanced company
with foreign investors” (2007).
Success on three legs
For the Asian
market, Turck
produces products that meet
German quality standards in
Tianjin, China
Last but not least, due to the start-up of both subsidiaries, Turck Tianjin has been able to reach numerous
key industries on the Chinese market in the past 14
years. Today, customers in the automobile industry,
the iron and steel industry, the tobacco industry and
many other industries rely on the know-how and
solutions from the German automation supplier. N
Even Chinese
automobile manufacturers rely on
the solutions of the
market leaders for
inductive sensor
technology
more @
1_2009
18 T r e n D _ W i r e l e s s
Author
Frank Humpert is a
product specialist for
interface technology
at Turck Germany
in Mülheim
Webcode | more20905e
Regardless of
whether point-to-point,
point-to-bus or
bus-to-bus – Turck is a
one-stop shop for
connectivity solutions
Wireless Transparency
Turck is expanding its portfolio for the physical layer with wireless
components that offer new options for asset management
19
G
erman sensor, fieldbus, interface, and
connectivity specialist, Turck, is expanding its product portfolio for the physical layer by adding wireless transmission products. The wireless series that Turck is introducing
at the 2009 Achema tradeshow supports a multitude of signals – from analog data to binary contacts and resistance measurements (temperature,
humidity), to digital protocols via rS232 or rS485.
Flexible connection architecture enables costeffective use with simple and complex automation
tasks.
Depending on the application, a customer has
the choice between a point-to-point connection – a
gateway with one node – or a network architecture
in which one gateway can operate up to 99 nodes.
To implement simple retroactive measurements or
data transmissions, the point-to-point connection
is the optimal solution, one that can transmit up to
eight binary inputs and four binary outputs or four
analog signals. More complex automation tasks can
be performed in a network architecture through the
wireless transmission of digital protocols via rS232
or rS485. In this way Turck provides the option
of transmitting all data wirelessly to a remote I/O
station.
Major automation potential
With the use of wireless technology, customers
can fashion their supply chain management more
effectively and reduce costs by avoiding exten-
N
 Quick read
The total costs of a process engineering system rise and fall with
machine availability, process reliability, and the necessary transparency for this purpose. With gateways and nodes for wireless
communication, Turck will soon make it possible to reliably transfer
data in the physical layer without expensive cabling. Users have the
choice between a simple point-to-point solution and network variants for more complex applications.
sive wiring. Frequently, machine operators request
additional measured values, but these are often
too expensive to record and transmit using classic wiring, such as in the case of lubricant monitoring in pumps. With IP67 rated gateways and
nodes, such difficult and expensive-to-access
machine areas can now be integrated into higher-level process control and asset management
systems.
For example, feedback from valve settings offers
a major automation advantages. Specifically for this
application, Turck will soon be offering a combination of wireless communication and a dual sensor,
which is able to detect the position of almost any
drive in process automation. This will allow users to
extrapolate additional measured values viably.
more @
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20 T r e n d _ W i r e l e s s
Using wireless data transmission, previously
difficult-to-access machine areas can now be
integrated into the asset management system
attracting attention in process engineering and are
more than just an overused catchword in the new
economy.
In fact, assets have been playing a strategic role
in process engineering and process automation. For
many companies at locations with high operating
costs, constant machine management is an important factor in being able to compete against companies based in low-wage countries. Ultimately, all
processing costs will rise or fall in inverse proportion
to machine capacity. In order to increase machine
capacity and thereby reduce costs, operators need,
in addition to reliable components for the physical
layer, equally efficient management and diagnostic
tools – so-called asset management systems.
The more comprehensively the system can query
and manage the diagnostic information on the machines
and components in use, the more efficient the system
is. The fundamental principle: Based on standardized
communications protocols, operators should be able
to access information concerning the field devices used
and components in the physical layers – meaning the
interface between the field devices and the higher-level
process control system – at any time and regardless of
manufacturer or area of application.
Process reliability with FDT/DTM
The wireless
gateways can
operate up to
99 node points
The wireless components authorized for Atex Zone
1 make it possible to diagnose and manage assets
even in explosion-protected areas, such as temperature measurement in steam pipes, corrosion
measurements or simple pressure, filling level or limit
value measurements.
An additional benefit is that the components
of the wireless family optimally use the generally
available frequency bands.
Thanks to the standardized transmission procedures TDMA (T ime
Division Multiple Access
process) and FHSS (Frequency Hopping Spread
Spectrum), data backup
and reliability are no longer deal-breaker criteria
for the use of wireless transmission technology in process automation.
The new wireless components from Turck also offer
complete compatibility with the FDT/DTM concept,
which, like the PC device manager, makes it possible to easily manage parameterizing and diagnostic data. The biggest advantage of FDT/DTM
software: The user no longer has to deal with managing the diagnostic data or the incompatibility of
different “drivers” (so-called DTMs). Instead, users
can concentrate entirely on the content of the data
obtained, and thereby the plant's status - based on
a comprehensive visualization program (e. g. PACTware). N
Asset Management
enabled
Universal asset management concepts – defined as
the monitoring and management of assets used within a
company – are increasingly
The FDT/DTM concept supported by numerous Turck products facilitates
efficient asset management of the physical layer
21
„
“
Standardization is the
Name of the Game
As editor-in-chief and publisher of the PROCESS magazine
and its online portal, process.de, Gerd Kielburger is in constant
dialog with manufacturers and users of wireless solutions. In this
interview, the process specialist talks about the opportunities
and risks of wireless communication.
Mr. Kielburger, a lot has been written and discussed on wireless communication in process automation.
In the meantime, have noteworthy
applications also been realized?
First of all, it must be said that wireless
communication has made a major developmental advance in process automation in a relatively short period of time.
The topic has arrived on the market and
almost all equipment suppliers have,
in the meantime, added wireless products to their portfolio. That is the positive message. On the other hand, the
process industry is known to be more
reserved when it comes to dealing with
new technologies. In light of this, the
acceptance of wireless communication
in field devices is not yet as high as the
marketing strategists with the equipment
supply companies would like to see. We
are moving right now in this field. But I
am sure that acceptance will increase
considerably with additional empirical values from the currently numerous
pilot projects. Due to the diverse areas
of application for this technology, users
simply have to experience it for themselves. And most that do have come out
of it with positive results.
What are considered the ideal
application areas for wireless communication?
Wireless communication is still considered ideal for difficult-to-access areas
out in the field, well known examples
include tank farms, pipelines, or standalone pumps in water supply systems.
Furthermore, there are numerous individual applications that deliver very positive results. Currently, however, no one is
truly propagating massive use in existing chemical plants as a replacement for
already existing cable connections.
more @
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What do you see as the limits of this
technology?
If you really want to control machines via
wireless systems, complex requirements
must be met that are currently not yet
solved. In this case, users want to know
that communication works reliably even
under difficult conditions and expect the
corresponding statements from manufacturers. In my view, that is why the primary use is initially focused on monitoring
and diagnosis tasks.
What opportunities, but also what
risks, does wireless communication
offer?
Opportunities for users exist wherever
measuring points make sense and are
necessary, but are difficult to reach, cannot be reached or can only be reached by
disproportionately high expenses using
cable connections. These include difficult
to overcome obstacles between the measuring point and the area of need, as well
as mobile or temporary applications. In
this context, I would not talk about risks,
rather about increased requirements. So,
for the processing industry, topics like
access protection, EMC compatibility,
explosion protection, but also ruggedness are of absolute importance.
In your view, what homework do
manufacturers still have to do?
Obviously, standardization and interoperability are essential factors concerning
this topic. At the moment, users have
to decide to opt for Wireless Hart or the
SP 100.11a standard for their particular situation. This makes users nervous. I
believe that manufacturers still have a bit
of homework to do in terms of getting a
handle on the real-time applications, as
well as autonomous power supply in field
devices. N
For 14 years, Gerd Kielburger
has been managing PROCESS
magazine and its associated
online portal, process.de. After
studying earth sciences, he
began his career as an editor
with the leading publication
“WLB Wasser, Luft und Boden” in
Mainz, Germany. Five years later,
he switched over to the VogelVerlag in Würzburg, Germany, in
order to build up the PROCESS
brand, now operating in three
languages (German, English and
Chinese).
www.process.de
22 T R E N D _ R F I D
I N P R O C E S S A U T O M AT I O N
Author
Walter Hein is the
product manager
for RFID at Turck
Germany in Mülheim
Webcode | more20906e
Whether in the pharmaceutical industry or in
the oil & gas sector,
reliable RFID solutions
open up new areas
of application in
process engineering
RFID in Hazardous Areas
Radio frequency identification (RFID) opens up new options in process
engineering – from intellectual property rights to preventive maintenance
W
hile the automation and streamlining potential of RFID radio-based
identification technology has long
been used in factory automation, their use in process automation is still not a standard. Up until
now, extreme environmental conditions, such as
high temperatures, pressures, and explosion-risk
atmospheres have been insurmountable obstacles, yet more and more, powerful and robust tags
and read/write heads are opening up new areas
of application. When it comes to intellectual property rights, production monitoring and condition
monitoring, RFID offers major advantages compared to the optical identification methods, such as
barcodes – and the use of this technology spans
many industries, including applications in the oil &
gas, chemical and the pharmaceutical and food
industries.
23

 Quick read
Thanks to temperature-insensitive tags for Zone 1, mobile reading devices and Zone 2 Remote I/Os,
RFID technology can now also be used in process automation. The radio-based identification opens
up many new opportunities ranging from the monitoring of coupling stations, the labeling of installation components, and the maintenance of drill piping or pipelines.
Impervious technology
Unlike conventional auto ID methods, such as barcodes or the data matrix code, the transmission of
information using electromagnetic radio waves is
generally less sensitive to environmental influences.
While printed labels attached externally to the product become unusable by the time they are exposed
to high temperatures or moisture, special RFID tags
and mobile reading devices make it possible to use
RFID systems even under the toughest conditions,
for example, in the autoclaves of the food industry
or on the drill pipes and pipelines in the oil & gas
industry.
RFID solutions adapted to meet the customer's
application, such as the Turck BL ident high-temperature system, offer the user additional benefits above
and beyond identifying individual products, batches
or machine parts. BL ident permits read/write heads
to be operated simultaneously and without interruption in HF and far-ranging UHF frequency bands
– using the same interface modules. The higher frequency UHF band (865 to 868 MHz) permits ranges
of up to three meters. Because BL ident can also
handle “group detection”, numerous tags can be
detected without experiencing air interference. This
feature makes RFID technology applicable in warehousing logistics, as well as for intellectual property
rights in the pharmaceutical industry.
free and “on the fly” reading is reduced defects and
delays in incoming and outgoing goods, which ultimately reduces costs.
RFID solutions in process engineering are used
for more than simply guaranteeing product reliability. Robust and powerful systems are also ideal for
use in the main field of process reliability. In close
cooperation with users in numerous fields of process engineering, Turck can develop individualized
Intellectual property rights using RFID
The issue of consumer protection is more televant than ever. According to estimates from the
World Health Organization, every tenth medication
sold worldwide is counterfeit. Due to the dramatic
increase in product piracy in the past few years, both
the American Food and Drug Administration (FDA),
as well as the EU Commission, require continuous
monitoring of the manufacturing and distribution
chains of medications and foodstuffs.
RFID tags mounted visibly or invisibly on the packaging materials with unique tamper-proof and forgeryproof identification numbers, allow manufacturers and
consumers in hospitals or pharmacies to track the
medications along the entire distribution channel and
to verify their authenticity. The kicker: The new UHF
technology from Turck can easily be used with existing HF systems.
UHF tags are also less expensive compared to
HF tags, which makes them better for applications
with high volumes. The additional benefit of contactmore @
1_2009
identification solutions for demanding applications.
For example, Turck has worked out a solution, that
facilitates ongoing asset monitoring and records the
changing external parameters, such as environmental temperature or correct machine settings. This is
done through the integration of RFID sensors and
wireless transmission technology.
Tags for Zone 1
At the Achema trade show on Chemical Engineering,
Environmental Protection and Biotechnology, Turck
will introduce a complete RFID system for explosionrisk areas – among them the first intrinsically safe
tags that open up numerous new application areas
including use in Zone 1 – from coupling monitoring
at coupling stations, to the continuous identification
of proprietary installation components and including
preventive maintenance of drill pipes or pipelines. N
Based on the reliable
BL20 fieldbus stations, Turck will be
introducing a complete RFID system
for use in hazardous
areas at the Achema
Congress
24 T R E N D _ I M A G E
PROCESSING
Author
Markus Bregulla is
the product manager
photoelectric
and ultrasonic
sensors at Turck
Germany in Mülheim
Webcode | more20907e
The Presence Plus Pro
camera system with
separate evaluation
unit is ideal for
demanding applications
in which the lowest
deviations in color
or form have to be
controlled reliably
Visionary
New vision sensor from Turck's optic partner Banner combines camera
system performance with simple sensor operation
F
rom localization to detecting bar or data
matrix codes and optical character detection, powerful image processing systems
support numerous processes in production and
logistics. Based on the complex interplay between
N
 Quick read
Easy to operate with the highest functionality: With the Banner Vision
systems, users can individually implement certain image processing
systems based on the requirements of their application without much
cost and effort. The newest highlight is the iVu series that Turck introduced at the Hanover trade show. As a Vision sensor with integrated
touchscreen, iVu can be configured without a computer.
optical/electronic components and the respective
application environment, the use of high quality hardware is frequently associated with high initial cost
and effort. Without programming skills or proprietary
computer software, it is not usually possible to install
or parameterize the image processing systems. Banner's vision products eliminate this problem.
Flexible complete package
With the Banner camera series Presence Plus, Turck
has added to its product portfolio a flexible image
processing system for demanding vision applications. Regardless of whether high resolutions are
requested, particularly fast inspection speeds or
the distinction between color features – the various
25
designs in the P4 series that can be installed horizontally and vertically (Omni, Geo, Area, Edge and
BCR) are suitable for a multitude of different detection tasks. Using a pre-configured graphic user interface, users can easily set up the inspection parameters with a simple mouse click. All you have to do is
focus the camera, highlight the object to be recorded
and select the inspection features and tolerances –
and done.
The image processing system Presence Plus Pro
combines the application options of the P4 series
with functions for pattern detection and counting, as
well as flexible input and output configurations. The
compact Vision solution, available as an option for
the IP68 protection class with separate evaluation
units, is ideal for demanding applications in which
the lowest deviations in color or shape have to be
controlled reliably and disruption-free.
Different software position, image processing and
analysis tools make the Presence Plus Pro an affordable and, nevertheless, highly functional solution.
With its help, users can verify, for example, whether
color coded fuses of certain ampere strengths were
correctly installed in the fuse boxes or whether foam
upholstery and plastic screws were snugly fit into the
fixtures paneling.
Parameterizing per touchscreen
With the world's first Vision sensor with integrated
touchscreen, Turck has demonstrated that the use
of powerful image processing solution does not necessarily have to be associated with great effort or
expense. The “iVu” is simple like a sensor and powerful like a camera system. The iVu series combines the
benefits of both detection technologies in one compact housing that is easy to install.
The Vision sensors consist of one camera with
CMOS image processor (resolution: 752 x 480), a
2.7" LC display, as well as an 8-pin M12x1 connection for the switching output and the USB connection
for uploading and downloading machine settings or
updated software. Different lenses ranging from 8 to
25 mm are available, as well as different lighting systems (red, blue, green, or red) and color filters. Due
to its compact structure and intuitive operation via
the touchscreen, even inexperienced first-time users
can install and learn to use the Vision sensor quickly.
Using the menu-driven parameterizing software, all
sensor functions and camera settings can be configured directly on site without the user having to rely
on the computer.
Thanks to this flexibility, the Vision sensor is
perfectly suited for a multitude of different detection
tasks that once required time-consuming parameterizing via computer software – from code detection
in the pharmaceutical industry, label inspection and
content checks in the chemical industry, to checking
weld nuts in the automobile sector.
Despite this high functionality, the Smart Vision
system, which Turck and Banner introduced at the
Hanover trade show, is considerably more appealing in
more @
1_2009
The new Vision
sensor is delivered
with lighting (IR,
red, blue, or green)
as a standard feature, but is also
available without
terms of price than other image processing solutions,
not only as far as acquisition costs go, but also due to
the free software and firmware updates and also the
operating costs. This means that the iVu series closes
the gap between sensor-based detection solutions
and powerful image processing systems.
Summary
Thanks to the iVu, Turck has closed the gap between
Vision cameras and opto sensors. The Vision sensor
product group that emerged in this way combines
the performance capacity of the camera systems
with the simple handling of sensors. It takes just a
few minutes for even inexperienced users to install
and learn to use the iVu Vision sensor so that numerous applications can be implemented – from the
label and warehouse inspection to the batch code
inspection and lock detection. N
Install – learn – detect: The new iVu is as easy to
operate as a sensor
26 A p p L I C AT I O n S _ R F I D
Author
Matthias Schick is
a sales specialist
at Turck Germany
in Mülheim
Webcode | more20950e
HKM (Hüttenwerke
Krupp Mannesmann)
produces preliminary
products used in steel
production in Duisburg,
Germany – so-called
slabs or billets
(round steel bars)
Sensitive Weightlifters
BL ident RFID system guarantees precise crane movement down to
the centimeter at Hüttenwerk Krupp Mannesmann
I
t is hot at the iron and steel works company
Hüttenwerke Krupp Mannesmann GmbH
(HKM) in Duisburg, Germany. As one of the
leading steel manufacturers in Europe, the company delivers preliminary products used in steel
processing, so-called slabs or billets (round steel
bars), to its partners, such as Thyssen Krupp Steel
AG. In order to manufacture these products, melted
metal must be transported, mixed, and processed.
The raw materials required for steel production
are transported in tough steel tubs, called pig iron
ladles, through the huge warehouse and production halls. Depending on the ladle, between 90
and 425 tons have to be moved in the process
– a task that can only be performed by a giant
crane.
27
Overall, HKM has about 50 giant cranes in use, ten
of which are used for the transport of liquid materials high above the hall floors. If something goes
wrong, under the rough and dusty conditions on
the steel formation, the best case scenario results
in a lot of lost time; in the worst case scenario, it is
damaged caused by the hot liquid material or the
bulky raw iron ladles and the related costs.
more @
1_2009

 Quick read
At the HKM steel and iron works in Duisburg, Germany, if the liquid raw
material does not flow where it is supposed to, the resulting damage is
very serious. In order to avoid this scenario, HKM verifies the position
determination of a transport crane using the RFID system from Turck.
28 A p p licatio n s _ R F I D
An RFID readwrite head
mounted near
a crane rotor
disk records
the signals from
the tag mounted
on the rail
Calibrating using RFID
“
Even if we do
not completely take
advantage of the
comfort of the BL
ident system, this
solution is unbeatable
for our control purposes.
”
Wilhelm Leurs,
Hüttenwerke Krupp
Mannesmann
Because of the high temperatures, the steel producers at HKM have therefore relied on the high temperature solutions from Turck. With the BL ident RFID
system and special sensors with an expanded temperature range up to 100 ˚C, the hot ladles can be
transported within the production halls precisely to
the centimeter and tracked so that expensive errors
during transport or when filling with raw material can
be avoided. “According to the motto, “install and forget”, the Turck products were easy to install, integrated wonderfully into the existing S7 controller and
have been operating error-free so far,” says Wilhelm
Leurs, technician in the crane maintenance department at HKM.
Turck's BL ident RFID solution meets an
important control function on the BS6L crane,
which transports the emptied ladles to the filling
area where they are cleaned and then reheated, if
required, in order to be able to hold liquid raw material again. About 16 meters above the floor, sitting
Reference points: The RFID tags are mounted on
specified positions of the crane's travel path
in a small cockpit, the crane operator controls the
machine with the help of the monitor. There are no
longer any positioners on the ground; the crane's
movements and positions are visualized and displayed on the monitor. Visualization helps the crane
operator position the crane when picking up and
setting down loads, which requires a high level of
precision from the system.
Rotary position transducer
prone to slack
In order to move the crane in a controlled manner
over the approximately 400 meter-long distance
between the pick-up and filling location, a rotary
position transducer is installed on a rotor disk which
records the movements of the crane and forwards
them to the main control unit. This approach is not
without its problems, because the travel sensors
detect the position of the crane only from the actual rotation of its huge rotor disks. And because the
steel wheels of the crane run on steel rails, a certain
The signals are transmitted from the read-write heads
to the control unit via the Turck I/O system BL67
29
amount of slack cannot be ruled out. This results in
an inaccuracy that the travel sensors cannot compensate for.
The “missing” centimeters can lead to serious
errors at the pick-up and drop-off areas at the latest, but makes it impossible for the crane operator
to accurately pick up or set down the ladles. This is
where the BL ident RFID system comes into play:
A Q80 read-write head is mounted near a crane
rotor disk and records the signals of the transponder
mounted at specific points on the rails, thus allowing millimeter-precise location coordination with the
travel sensors in the main control unit – regardless
of slack. Using the known positions of the tag, the
control unit can calibrate the signal of the rotary position transducer and therefore reliably prevent any
influence on possible slack. The tags are especially
designed for use in high temperature environments
up to 210 °C.
HKM has selected a control system with low
installation and maintenance costs that always
checks the signals of the travel sensor and, if necessary, can update them in the control unit. The BL
ident system from Turck not only prevents serious
accidents, but also makes efficient supply chain
management possible. “In the spirit of complete
material monitoring, it is important for us to know
precisely where the crane puts its load down so
that we can determine where each of the individually numbered ladles are located,” says Leurs.
The system works so reliably that the HKM is
planning on equipping all of its giant cranes that are
used to transport raw and end products with the BL
ident solution from Turck. This amounts to 30 giant
cranes that guarantee the reliable transport of material in the company's steel production halls in Duisburg, Germany. “Even if we do not completely take
advantage of the comfort of the BL ident system,
this solution is unbeatable for our control purposes,” summarizes Leurs.
Sensors instead of positioners
In addition to the RFID solution, Turck's inductive sensors have also proven reliable for use in
this tough iron and steel works environment. Two
special sensors that meet the IP68 protection
class are mounted on each of the massive lifting
hooks, which the crane uses to lift and transport
the foundry ladles, weighing several tons. These
sensors record whether the lifting bolts on the
foundry ladles lie exactly and safely in the laminated hooks. Here, too, from his cockpit 18 meters
above the floor, the crane operator has difficulty
detecting whether the ladle is correctly placed
on the hook. The use of two sensors placed at
a 90° angle guarantees that the bolts are reliably
placed across the entire surface of the laminated
hooks.
For Leurs, the heat, shock, and vibration-resistant S 100 sensors from the BI15-K series turned
out to be essential and reliable control tools. “We
more @
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have never had problems with the Turck sensors
and will therefore equip all cranes that transport liquid raw materials with these sensors,” adds Leurs.
Especially due to their high measured switching
distances of up to 15 millimeters, the Turck special
sensors are suitable for use under the tough conditions in steel production where slag and fine metal
dust get into the robust machines and can hinder or
distort sensor readings. N
Clever safety
solution: Four
Turck sensors
in the laminated
hooks ensure that
the lifting bolts of
the foundry ladles
were precisely
placed
30 A P P L I C AT I O N S _ R F I D
Author
Qiang Lin is a
RFID specialist
at Turck China
in Tianjin
Webcode | more20951e
Seeing
through the
Smoke
BL ident improves warehouse management in Chinese cigarette factories
N
o other country in the world produces
more blue smoke than China. With a
consumption rate of 1.5 billion cigarettes
per year, the Chinese make up about 30 percent of
the world's cigarette consumption. Although foreign
tobacco companies are represented in China, the
national cigarette brands still have the largest market
share. Among the most famous brands is Baisha,
which, among Chinese smokers, is comparable to
Marlboro in Western countries.
For the company's plan to modernize their warehouse management system and to restructure their
supply chain management to make it more efficient,
the Baisha Group placed its trust in the automation
know-how of China Post Science and Technology
Co., Ltd. (CPST). The company, headquartered in
Beijing, employs more than 400 people in research,
consulting, and system integration.
Its scope of services includes the planning and
integration of logistics and distribution systems, as
well as the implementation of higher-level information and control systems. In the past few years,
CPST's research and development center has also
supported the Chinese government in modernizing
the postal services country-wide and, in this context, completed more than 800 individual projects
for RFID applications, including high-speed sorting
systems and horizontal conveyor belts.
Challenge of diversity
The diversity of the products used in cigarette production quickly turned into a major automation challenge. This is because in a large tobacco factory, like
Truck's BL ident RFID
system ensures the
right transparency in
the high bay warehouse
at the Baisha Group
Simple assembly: Most read-write heads are
available in the standard sensor configuration
31
Turck total package: BL20 remote I/O system (l.), engine starter (m.) and BL ident Profibus Gateway (r.)
the Baisha plant in the province of Hebei, numerous cigarette brands are produced and the multiple
components of the various end products have to be
constantly stored in large amounts. These include
different tobacco types, cuttings, aromas and other
additives, in addition to the different packaging.
In 2007, in order to structure the intralogistics
of the tobacco factories more efficiently, CPST introduced the BL ident RFID solution from Turck into its
numerous production facilities - besides the Baisha
Group, other firms such as Jinan General Tobacco
Company and Shandong Qingzhou Tobacco Company used CPST's consulting services.
The RFID technology offers plant operators
many benefits in supply chain management, regardless of the respective warehouse equipment. In contrast to the previously used barcode, which enables
the commodity group (e.g. tobacco container) to be
identified based exclusively on a serial number, the
RFID tags with a memory capacity of up to 2 kByte
(FRAM) can also record relevant information such as
batch, receipt date or the most recently performed
processing steps.
“No programming effort”
The BL ident system, which is sold in China by the
company's subsidiary Turck (Tianjin) Sensor Co. Ltd.,
has proven itself not only in terms of uniform information management, but also as a manageable and
comprehensive solution. The modular configuration
of the RFID system convinced CPST employees and
warehouse operators very quickly: “The Turck products were very easy to implement,” says Cunyu Li,
responsible at CPST for electrical installations. “Connecting it to the controller was very easy and there
was practically no additional programming effort. I
would not have thought so beforehand.”
In order to modernize and make warehousing
and intralogistics more efficient at the Baisha Group,
the CPST project manager opted for Turck's Q80
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read-write heads and the reliable BL67 remote I/O
system. Mounted directly adjacent to the transport
belts, the Q80 read-write heads detect the tags
attached to the transport containers of the incoming
and outgoing warehouse goods. The read-in data is
subsequently forwarded from the gateways of the
I/O nodes via Profibus to the higher-level warehouse
management system
Optimized to the application
For system integrators and users, the Turck complete solution offers numerous advantages: The flat
tags can be easily attached to metal, the combination of suitable tags and read-write heads permits
application-optimized ranges from the read-write
head to the interface module, the robust components are uncomplicated to install on-site.
Moreover, the BL ident system makes future
expansions in supply chain management possible.
The system supports many fieldbus protocols –
from Profibus-DP to DeviceNet and even Ethernet/IP
– as well as numerous signal forms, such as digital and analog I/O modules, RS232/422/485 interface modules and high-speed counter modules.
BL ident allows warehouse operators to also fall
back on existing remote I/O structures in case of
future automation plans – and thereby avoid additional implementation and warehousing costs N

 Quick read
As an external system integrator, China Post
Science and Technology Co., Ltd. (CPST) creates
strategies for increasing efficiency for numerous
Chinese companies. In order to improve warehouse management at national cigarette factories, the specialists have been using the BL ident
RFID solution from Turck.
“
Connecting it to
the controller was
very easy and there
was practically no
additional programming effort.
I would not have
thought that
beforehand.
”
Cunyu Li,
China Post Science and
Technology Co, Ltd.
32 A P P L I C AT I o N S _ S e n S o r
technology
Author
Deyou Yang is a
product manager
at Turck China
in Tianjin
Webcode | more20952e
In its production lines
in Changchun in northeast
China, FAW-VW Automobile Co., Ltd. is producing
sedans based on European
models like the Golf, Jetta,
Bora or Passat
To the Point
FAW Volkswagen relies on uprox+ sensors for reliable and precise welding and
assembly processes at its automobile production lines in China
S
teel body or aluminum frame? Magnesium interior or plastic interior? Wood
trim or carbon accents? The selection
of the materials used in automobile manufacturing
is as great today as the expectations of the automobile purchasers. In the end, the car has become
much more than a simple mode of transportation for
most customers – it has become a status symbol
that should be equally high-quality as well as individual.
In order to be able to meet the growing expectations of customers and simultaneously ensure
efficient production, the automobile production
lines have to be constantly modified, remodeled or
expanded. New materials, improved production pro-
33

 Quick read
Exclusive, high quality, and individual - with the increasing demands of
the purchasers, the demands placed on automated production lines of
vehicle manufactures have also risen. New materials, production technologies, and levels of automation require automation solutions to be
constantly updated. For welding and assembly processes in its Chinese
production plants, FAW-VW found a versatile and reliable solution in the
uprox+ sensors from Turck.
Ltd. – relies on sensor technology from Turck. In its
production lines in Changchun in northeast China,
FAW-VW is producing sedans based on European
models like the Golf, Jetta, Bora or Passat. Founded
in 1991, FAW-VW has become one of the major
Chinese automobile manufacturers with a plant
value of approximately 3 billion Euro and a production capacity of 1,000 manufactured cars per day,
as well as additional capacities for vehicle and parts
export.
High demands placed on sensors
During the course of such breathtakingly rapid
development in the Chinese automobile industry,
customer demands have risen with regard to quality,
functionality and efficiency. This has led FAW-VW –
like all automobile manufacturers in the end – to use
new materials and technologies in order to facilitate
the flexible production of different vehicle types and
models at one location. Equally high were the automobile manufacturer’s requirements with regard to
the sensor technology used. In order to be able to
detect workpiece positions in the various stages of
automated production, such as stamping, painting,
welding and final assembly, the sensors have to be
robust, versatile, and cost-efficient – requirements
that the Factor 1 sensors from the uprox+ product
line fully meet.
cesses, and expanded automation potential are also
putting higher demands on the automation solutions
already in use. Due to the diversity of the materials used, the production steps performed, and the
machines used, in the end the efficiency of a production line stands and falls with the plant capacity
and thereby with the flexibility and reliability of the
automation components used.
That is why, in order to ensure the efficient
production of high quality automobiles like VW’s
new Sagitar or the Magotan vehicle lines, FAWVW Automobile Co., Ltd. – a joint venture between
the Chinese government-owned First Automotive
Works, Germany’s Volkswagen AG, Audi AG and
Volks­w agen Automobile (China) Investment Co.,
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One for all: Turck’s ferrite-coreless uprox+ sensors have the same high
switching distance on all metals
34 A pp L icati o ns _ S e n s o r
technology
CK40 series) – thus offering high degrees of freedom for installation and area of application. A further
advantage of the Factor 1 sensors that are sold by
Turck (Tianjin) Sensor Co., Ltd. (TTS) in China is the
fact that with the few sensor types that are suitable
for many applications within the production line, the
automobile manufacturer was able to set up simple
and cost-efficient warehousing.
One of the hardest areas of application in the
FAW-VW plants is welding assembly. In the overall
production line, the individual parts of the various
sedan models run through up to 5,000 spot welding steps. For monitoring the automated motion
sequences, FAW-VW relies on the sensors from
Turck’s MT series. Mounted on the robot arms, the
special sensors coated with teflon continuously
check the position of the robotics in relation to the
workpieces. In welding assembly, not only high
switching distances are required in order to be able
to detect the position of the workpieces early on
and, if necessary, correct them, but also excellent
shielding against external environmental conditions.
Because uprox+ sensors do not contain ferrite core,
they are equally insensitive to strong magnetic fields,
like those that develop during the welding process,
as they are to flying sparks or mechanical wear.
Installation at any angle
For recording the position on cross-bars in final
assembly and in the paint shops, FAW-VW relies on
uprox+ sensors from the QV40 series, which can reliably detect the presence or absence of metals up to
a distance of 50 mm. However, the square-shaped
sensors that are simple and uncomplicated to install
via a mounting clamp perform their services reliably
not only with regard to determining the position on
the cross-bars, but they can also be used literally in
any angle of the production line.
Because their active surface can be positioned
in five different directions manually without tools,
the QV40 sensors can be comfortably and quickly
adapted to the respective applications and environmental conditions. Like the MT series, the QV40 sensors allowed production engineers at FAW-VW to
cover detection applications in the entire production
line using a low number of product types. N
Even welding
processes have
nothing on the
uprox+ sensors
mounted on the
robot arms

 The user
Factor 1 on all metals
Thanks to multi-spule technology, the sensors
designed to meet the IP68 protection class detect
all metals without a reduction factor – regardless of
whether it is iron, stainless steel, copper, aluminum
or brass. Not only that, in comparison to conventional ferrite core sensors, uprox+ made it possible for FAW-VW to detect all metals used in the
production lines with considerably higher switching
distances up to 50 mm (FAW-VW uses the Ni50U-
The FAW-VW Automobile Co., Ltd. is a joint
venture of the Chinese government-owned
First Automotive Works, the German company Volks­wagen AG, Audi AG, and Volkswagen Automobile (China) Investment Co., Ltd.
Based on European models such as the Golf,
Jetta, Bora or Passat, FAW-VW has been producing sedans and vehicle parts for the Asian
market since 1991 – more than 1,000 vehicles
per day.
www.turck.com
UÊPrecise
Precise detection
Also under the most adverse conditions.
The complete programme includes
sensors and components for all
applications.
CONNECTIVITY
INDUCTIVE
UÊSafe
Safe connections
From connectors right up to actuator/
sensor boxes: The connection technology portfolio made by TURCK leaves
nothing to be desired.
FLUID
PHOTOELECTRIC
IP20
IP67
UÊPerfect transmission
No matter which fieldbus you use:
TURCK offers a complete programme
for fieldbus technology.
UÊEfficient automation
RFID is only one example of how
TURCK products and know-how
guarantee optimal automation solutions
for your systems.
RFID-SYSTEM
Sense it! Connect it! Bus it! Solve it!
Hans Turck GmbH & Co. KG
Witzlebenstraße 7, 45472 Mülheim/Ruhr
Tel. +49 (0) 208 4952-0, Fax -264
E-Mail [email protected], www.turck.com
36 A P P L I C AT I O N S _ F I E L D B U S
TECHNOLOGY
Author
Marc DiSera is the
product marketing
manager in the network and interface
division at Turck USA
in Minneapolis
Webcode | more20953e
Compared to field
propagation, strictly
controlled propagation
conditions drastically
reduce growth down
to only 50 days
Minitubers at a Glance
Quantum Tubers monitors the atmospheric conditions in potato propagation
using the BL67 Remote I/O from Turck
F
rom a stem-cutting to a harvestable minituber for potato production in a maximum of
50 days – the method developed by Quantum Tubers Corporation in Wisconsin, USA, makes
the propagation of minitubers possible. The automated system for growing minitubers – developed
in cooperation with NASA and the University of Wisconsin – makes it possible to grow minitubers with
considerably shorter propagation times and thereby also lower production costs. Compared to field
propagation, this new method is not only consider-
N
 Quick read
In cooperation with NASA and the University of Wisconsin, Quantum
Tubers has developed a new bio manufacturing technology for producing minitubers. So that minitubers can grow quickly and be used in the
harvest, the atmospheric conditions must be monitored reliably in the
greenhouse facilities. In this process, Turck's BL67 fieldbus station with
IP67 protection class ensures I/O communication.
ably faster; the bio-manufacturing method geared
toward commercial production grows pathogen-free,
divisible minitubers which can serve as a year-round
seed source for potato production in the right location. The use of minitubers in potato production is
not new, however the previous procedure was either
very expensive and not suitable for the large demand
in industrial production.
Nine harvests per year
In contrast to field propagation, the sterile stem cuttings are cultured in controlled atmospheric conditions. Because the minitubers, depending on the
type, can be harvested after just 40 to 50 days, up to
nine harvests per year are possible.
The benefits of propagation under controlled
conditions are obvious. Instead of spending years
producing seed potatoes under field conditions,
which can be increasingly susceptible to degradation and pathogens – due to tubers being repeatedly
recycled for seed – new potatoes can be produced
37
for commercial production with the help of different
minitubers within just two years.
Propagation time reduced
However, the shortened propagation times of the
minitubers require optimal growth conditions – factors such as humidity, light, temperature, and CO2
content must be monitored continuously and failurefree. After the originally used flow sensors and isolation switches had proven too imprecise for this task
and prone to failure, the plant production specialists
in Wisconsin finally began using sensor, fieldbus, and
connection components from Turck.
In the largest automation market in the world,
sensor market leader Turck works closely with external sales representatives who are always located
near customers. One of those is Lawrence Jacob,
Senior Sales Engineer at MTECH Wisconsin Inc.
Jacob was able to convince Quantum Tubers of the
flexibility and reliability of the Turck solutions. That is
how a control system was developed that is exactly
tailored to the requirements of the proprietary biomanufacturing system. “Turck has been helpful in
making sure we have the right components for our
system, and has been there to help us iron out all
problems,” says Bob Britt, President and CEO of
Quantum Tubers. “Working with Turck saved us at
least a year of development time.”
The heart of the control system is the modular
BL67 remote I/O system. Made up of a gateway
for fieldbus communication and easy-to-integrate
I/O modules, the robust and flexible fieldbus station made it possible to record all measuring signals directly in the field and forward to the higherlevel controller, as well as transmitting the controller's
signals to the actuators in the opposite direction. A
total of twelve analog input modules (AI) register the
normalized electrical standard measuring signals for
humidity, temperature, light and CO2 content via the
basis module connections. They then digitalize these
signals and transmit them to the gateway via the
internal module bus – regardless of the higher-level
fieldbus protocol. Added to the remote I/O solution
are four digital output modules (DO) through which
Turck's FCMI flow meter guarantees that the plants
will be supplied with water and nutrients
more @
1_2009
the magnet valves for CO2 content, humidity, and
the fluid supply line to the spray nozzle system are
controlled.
Individual solution
With 4- and 16-channel output modules that are
connected via a standard M12x1 plug-in connector
with a switch box designed especially for Quantum
Tubers, the BL67 station further enables decentralized control of the light banks, circulating fans and
the cooling circuit. Besides standard C10 relays,
there are also special C10-A15X lighting ballast
relays from Releco in use that not even short-term
current peaks of up to 125 Amps can harm. “Before
using Turck products, we had a series of breakers
in a panel chocked full of electrical equipment, and
electrical fires were not uncommon because of proximity to wet conditions,” describes Britt.
In addition to the flexibility of the modular fieldbus station, the robust IP67 design as well as the
quick connection concept for Ethernet, supply and
field cabling were decisive factors for the selection
of the Turck components. “Implementing this system saved us six months of hands on time putting
the system into a big box,” explains the Quantum
Tubers CEO. “The best part about the system is that
it can easily be put into the hands of a third party
for installation, and they will be able to implement it
quite easily.” N
Flexible and reliable: The BL67
remote I/O system
forwards measurement and control
signals directly
in the field
“
Working with
Turck saved us
at least a year of
development time.
Bob Britt,
Quantum Tubers
”
38 A P P L I C AT I O N S _ F I E L D B U S
TECHNOLOGY
Cranes with Brains
BL67 remote I/Os work reliably in huge gantry cranes from ABB – the modular
fieldbus system withstands even the highest physical stresses
I
n operation, they make containers weighing thousands of tons appear to levitate. The
meter high rectangular blocks seem to glide
effortlessly from their storage locations to awaiting freight trains or goods carriages. Facades the
height of houses are built only a few meters apart
out of stacked freight containers awaiting further
shipment. Automated rail-mounted gantry cranes
(ARMG) or double rail-mounted gantry cranes are
regarded as the workhorses among the industrial
“weightlifters”.
Gantry cranes move millions of tons of freight
around the world daily. Behind this enormous transport effort is hidden a considerable amount of hightech. Gantries with track widths of over 40 meters
run virtually always automatically and can weigh
Author
Ulf Löfqvist is
an applications
specialist at
Turck Sweden
in Gothenburg
Webcode | more20954e
Tireless workhorse:
Gantry cranes move
millions and millions of
tons around the
world daily
between 200 and 350 tons. They can raise freight
containers to lofty heights of over 20 meters. In
conjunction with automatic transport systems, gantry cranes achieve a genuine tour de force in terms
of freight logistics. Sophisticated automation and
accessory systems ensure smooth goods handling
in all major seaports.
ABB Crane Systems is one of the leading suppliers of gantry crane technology. As part of a major
project, ABB is currently supplying automation
systems and electrical equipment for more than
100 ship-to-shore cranes intended to increase productivity in numerous Asian ports. Function tests and
final assembly are carried out at the Shanghai Zhenhua Port Machinery Company (ZPMC) in China, the
largest crane manufacturer in the world. By the end
39
of 2008, ABB had delivered 29 ARMG, two RMG and
seven ship-to-shore cranes for the port of Busan,
South Korea, alone. Additional projects include 20
unmanned, track-based container gantries for the
Taipei Port Container Terminal Corporation in Taiwan,
as well as 42 similar units and twelve ship-to-shore
cranes with dual hoist systems for Hanjin Shipping,
which are to be supplied for the Busan New Port in
South Korea.
Reliable and safe
ABB Cranes stand for safety and reliability. It's no
wonder, then, that the project managers take great
care in selecting all plant components. After all, only
if every individual part provides its service reliably can
the entire system function reliably.
Part of this overall system is the remote I/O
technology from Turck, which ensures reliable connections between the field devices and the controller level in the 73 automated gantry cranes in
the port of Busan. “The fact that we opted for the
Turck BL67 I/O modules is due to their high vibration resistance, as well as their drop and topple
characteristics,” comments Åke Adolfson, manager of Systems Engineering & Commissioning at
ABB Crane Systems. The reason for the demanding requirements: Despite sophisticated controller
technology, collisions between the head blocks
of the cranes and the containers can still occur.
The technology must be able to reliably and durably withstand the acceleration forces produced in
these cases.
The modular BL67 I/O system was manufactured with IP67 protection especially for use under
extreme conditions. It consists of a gateway and
expansion modules. The gateways are used for
communication with the fieldbus in use and are currently available for Profibus-DP, DeviceNet, CANopen
and Ethernet. Up to 32 expansion modules can be
connected to the gateway. The basic modules are
passive components and are simply snap-fitted into
the system. This produces a compact and mechanically stable unit that can be expanded at any time.
Thanks to the compact design of all BL67 components, the fieldbus nodes can be mounted in direct
proximity of sensors and actuators without taking
up a lot of space. N

 Quick read
Automatic rail-mounted gantry cranes are the
tireless industrial “workhorses”, handling millions
of tons of freight worldwide and operating virtually entirely automatically. So that these giants
function trouble-free, ABB Crane Systems has
added remote I/Os from Turck to its own I/O
solution. High vibration resistance, as well as
resistance to impacts, tipped the scales in favor
if the BL67 series.
Tough: Turck’s BL67 remote I/O system can take
the impacts and vibrations from the gantry cranes
more @
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“
The fact that we
opted for the Turck
BL67 I/O modules
is due to their high
vibration resistance
as well as their
drop and topple
characteristics.
”
Åke Adolfson
ABB Crane Systems
40 A p p L I C AT I O n s _ F i e l d b u s
Technology
Author
Bo Liu is
a business
develoment
manager at Turck
China in Tianjin
Webcode | more20955e
C
In 2004, the Tianjin
Chemical Factory
expanded its production
capacities with a new
plant that produces
vinyl chloride
monomer (VCM)
hina is the fastest growing industrialized country in the world in the chemical
industry. Between 2005 and 2007, the
chemical industry of the people’s Republic of China
was able to increase sales by almost 70 million Euro,
thus becoming the third largest chemicals manufacturer worldwide. The metropolis of Tianjin, with
a population in the millions, is benefiting from this
boom. In addition to numerous other chemical producers, the port city at Hai He has been home to the
Tianjin Chemical Factory – the largest Chinese producer of sodium hydroxide solution – since 1938.
Whether natrium hydroxide, monochlorobenene,
chloroform, epichlorohydrin or dichlorodiphenyltrichlorethane – the product portfolio of the Tianjin
Chemical Factory is impressively comprehensive.
These products are used in drain cleaners, solvents,
two-component adhesives and insecticide.
In 2004, the Tianjin Chemical Factory expanded
its production capacities with a new plant that produces vinyl chloride monomer (VCM). Vinyl chloride
– the most important raw material for manufacturing
pVC - is a poisonous, slightly combustible gas (igni-
41
The advantage of
the modular design
of the excom station: The up to 16 I/O
modules – including the power supply packs – can be
replaced during
continuous operation
in Zone 1
Intrinsically Safe Field
Communication
In the Tianjin Chemical Factory, excom remote I/O stations transmit temperature
measurement signals from the explosion-risk area reliably and efficiently
tion temperature about 435 °C), which first becomes
a solid and polymerizes after peroxides are added.
Because of these and other properties, temperature is the most important process parameter when
manufacturing VCM. Even the actual production
steps require controlled temperatures at all times.
Too low a temperature would not just lower the reaction speed of the intermediate products, it can also
destroy the catalysts.
That is why the Tianjin Chemical Factory uses
seven type E thermo elements for temperature measurement in each of the 44 transformation systems
more @
1_2009

 Quick read
In the VCM plant in the Tianjin Chemical Factory,
temperature measurement signals have to be
retrieved at 370 measuring points and forwarded to the controller level. Because classic pointto-point cabling would have been too expensive
and time-consuming, Turck delivered both an
efficient and comfortable solution in the form of
its intrinsically safe remote I/O system excom.
42 A p p L icatio n s _ F i e l d b u s
Technology
The excom remote
I/O, consisting of
power supply pack,
gateway, I/O modules,
and racks, can be
configured using 24 V
DC or 230 AC voltage
in which the addition of hydrogen chloride to acetylene occurs. Including the supply piping, a total of
370 measurements have to be transmitted from the
explosion-risk area to the process control level. A
task that the project managers could only have completed, in the case of classic point-to-point cabling
via interface technology, with high installation costs
and major maintenance expenses.
“
With excom,
we were able to
reduce the costs for
cabling by 40 percent
compared to our
original plan.
”
Wang Haiwen, Tianjin
Chemical Factory
230 V operation for long distances
With a total of six intrinsically safe excom remote
I/Os from Turck, the Tianjin Chemical Factory was
able to solve the problem efficiently and reliably. The
excom stations authorized for use in explosion-risk
areas for Zones 1 and 2 are marketed and sold in
China by the Turck subsidiary (Tianjin) Sensor Co.
Ltd. (TTS) and offered the plant operators in Tianjin
a major advantage: They can be installed and operated using either 24 V DC or 230 V AC voltage.
The latter is an enormous advantage primarily
with long signal paths compared to other remote I/O
stations, which are operated exclusively using 24
VDC. While, in some cases, much larger cable crosssections have to compensate for the voltage drops
that occur due to the longer cable lengths, Turck’s
excom I/O solution guarantees a stable power supply
even with cable lengths of several hundred meters.
This allowed the plant operators in Tianjin to achieve
considerable savings on the installation.
“With excom, we were able to reduce the costs
for cabling by 40 percent compared to our original
plan,” explains Wang Haiwen, an employee in system management. Excom was also particularly userfriendly in case of a potential module defect. The up
to 16 I/O modules can be replaced in Zone 1 during continuous operation. Thus, the remote I/Os
guarantee increased plant availability in the Tianjin
Chemical Factory.
Asset Management with FDT/DTM
In addition to increased availability, hot swapping,
and explosion protection, the system makes it possible for operators in China to comprehensively
HARD parameterize their field devices via the bus
line (Profibus-DP), as well as manage and diagnose
using the Field Device Tool (FDT) and Device Type
Manager (DTM): As a member of the FDT Group,
Turck supports the concept right from the start that,
like a PC manager, allows parameterizing and diagnosis data to be managed easily. The software’s biggest advantage: The user no longer has to deal with
managing the diagnosis data or the incompatibility
of different “drivers” (so-called DTMs). Instead, users
can concentrate entirely on the content of the data
obtained, and thereby the plant’s status - based on
a comprehensive visualization program (e.g. PACTware).
Just like the I/O modules, the constantly updated
excom DTMs offer a unique modularity that reflects
the flexible structure of the overall remote I/O station. With the DTMs, the plant operators at the Tianjin
Chemical Factory can manage the diagnosis data for
the racks (backplane) just as easily as the data on the
I/O modules used or even each individual channel.
This allows the plant operators to localize malfunctions in the field faster and reduce expensive downtimes in the production chain. Fortunately, such a
situation has not yet occurred at the VCM plant in the
Tianjin Chemical Factory. “Since installation in 2004,
communication via excom has been trouble-free,”
says Wang Haiwen with a look of satisfaction. N
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FIELDBUSES
REMOTE-I/O
Isolation, conversion, processing, transformation and conditioning of analog
signals. TURCK offers a large variety of
devices in different housing styles, from
DIN rail over 19“-cards to special
housing designs.
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Ê ,i“œÌi‡É"ÊÃÞÃÌi“Ã
The IP20 Remote-I/O solutions excom®
for application in zone 1 and BL20 for
zone 2 fulfill the specific requirements of
the process industry.
INTERFACES
WIRELESS
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From the multibarrier to connectivity
technology, TURCK customers can
choose from a comprehensive product
portfolio for FOUNDATION™ fieldbus
and PROFIBUS-PA.
RFID
CONNECTIVITY
Point to Point! Point to Bus! Bus to Bus!
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TURCK solutions for process automation enable integrated diagnostics of
the physical layer and therefore efficient
asset management – Safety made in
Germany.
Hans Turck GmbH & Co. KG
Witzlebenstraße 7, 45472 Mülheim/Ruhr
Tel. +49 (0) 208 4952-0, Fax -264
E-Mail [email protected], www.turck.com
44 A P P L I C AT I O N S _ F I E L D B U S
TECHNOLOGY
Author
David Fazzini is the
global director for
the pharmaceutical
industry at Turck
USA in Minneapolis
Webcode | more20956e
The instrinsically
safe excom station
facilitates the reliable
reception of about 50
signals from the new
filtration system
Easy Upgrade
Turck’s intrinsically safe remote I/O solution excom simplified adding a new
filtration vessel to an existing process
A
common challenge in the process technology and engineering group of Evonik
Degussa North America is how to add
process equipment in existing plants smoothly and
effectively without upsetting the installed process
control architecture. And, of course, the engineers
are expected to make those additions within budget
and on time. Evonik Degussa GmbH, a global leader
in specialty chemicals headquartered in Dusseldorf,
Germany, operates five plants in Canada and 28 in
the USA, the largest of which is in Mobile, Alabama,
with some 600 employees.
N
 Quick read
With the intrinsically safe excom remote I/O stations from Turck, Evonik
Degussa North America was able to integrate signals of a new filtration
system reliably and easily in Hopewell, Virginia, into existing process
control systems.
Mobile is also the home of the process technology
and engineering group, which was challenged in to
oversee the engineering and construction of a new
filtration system at the Hopewell, Virginia, site. This
plant specializes in personal care and surface specialties, including betaines used for hair care and
surface cleaners, fatty acid and fatty alcohol emollient esters used for sunscreens and deodorants,
and silicone surfactants used in the production of
polyurethane foam.
By the time the new filtration system was needed, the plant had migrated to a modern DeltaV distributed control system, which was connected to
field measurement and control devices with conventional wiring carrying the I/O. Adding more of the
same was not attractive to the progressive engineers
of the process technology and engineering group,
in part because the new filtration vessel was to be
installed in a Class I, Div. 2 hazardous area, meaning
all connections had to be protected to prevent the
possibility of an explosion. That was one important
45
Evonik Degussa was able to reduce
considerably the cabling and
maintenance costs in its new filtration
system in Hopewell, Virginia
factor mitigating the selection of a more advanced
solution – the use of the Turck excom intrinsically
safe remote I/O.
Excom is a state of the art system that collects discrete and analog I/O signals from remotely
mounted stations located in the hazardous area and
communicating that data via intrinsically safe Profibus-DP to the distributed control system located in
a non-hazardous area. The remote I/O is perfectly
suited for plant upgrades and equipment additions,
as it can be utilized even while the rest of the plant
may still be using conventional wiring between the
field devices and the control room. This allows new
processes to be implemented in a flexible, modular
way.
Turck's excom is a rack mounted remote I/O
system consisting of a Profibus-DP gateway module
and I/O modules for discrete, Hart analog and raw
temperature inputs. This system is designed for critical process applications where no single point of failure may be allowed to exist and all power supplies,
gateways and I/O modules are hot swappable under
load. Additionally, the 18-slot rack allows for Profibus-DP network line redundancy, as well as power
supply and gateway redundancy. For applications
subject to lightning and long network runs, such as
Status LEDs on gateway and I/O modules allow a
simple function diagnosis of the excom station
tank farms, Turck offers a Profibus-DP fiber optic
coupler. In addition to providing an intrinsically safe
system, this approach saves space, time and money
compared with traditional wired, centralized I/O.
At the plant in Hopewell, the Excom remote I/O
system was installed in a purged box near the new
filtration vessel. The box is air-pressurized to keep
contaminants out. Wires from about 50 devices
installed on and around the filtration vessel are connected to the remote I/O, which then connects to
the DCS via a Profibus-DP cable.
more @
1_2009
“This is where we saved money,” said Ken Mead,
process control engineer with the process technology and engineering group. “We ran only one cable
from the remote I/O to the DCS rack room, eliminating the need to install conduit and pairs of wires
from each field device to the marshalling cabinets.
This was about 35 percent less than the anticipated
engineering and construction costs with traditional
wiring, and we also got an intrinsically safe installation.” According to Mead, Degussa will also be able
to “piggy back” on the installation, using the fieldbus cable for additional I/O, if and when such a need
occurs in the future.
Commissioning the new filtration unit was another positive factor, and was about as easy as any
Mead had ever seen: “It didn’t take any time at all. It
was just like Turck told us – plug and play.”
The success of this project has led Mead and
the other process engineers at Evonik Degussa to
look for more opportunities to use Turck’s remote I/O.
“The installation in Hopewell was a big cost saver for
us,” explained Mead. “That included savings on conduit, explosion-proof fittings and construction. We
are very happy with the results, and we have some
other plants where we are considering doing the
same thing or something similar when new equipment is installed or older field devices are replaced.
It all went so well; that was a very easy upgrade.” N
“
The installation in
Hopewell was a big
cost saver for us. That
included savings on
conduit, explosionproof fittings and
construction. It all went
so well; that was a very
easy upgrade.
”
Ken Mead, Evonik
Degussa North America
46 A P P L I C AT I O N S _ I N T E R FA C E
TECHNOLOGY
Author
Holger Anders is a
key account manager
process automation
at Turck Germany
in Mülheim
Webcode | more20957e
In addition to this
natural gas station in
Bottrop, Germany, cars
can be refueled with
the flighty fuel
at about 800 other
natural gas stations all
over Germany
Accelerating Reliably
Schwelm Anlagentechnik trusts its natural gas fuel pumps and compressor
stations to interface technology from Turck
E
nergy-efficient, cost-efficient, and environmentally friendly - natural gas as a fuel
for vehicles pays off threefold. At about 800 natural gas stations, drivers in Germany can refuel with
the flighty fuel CNG (Compressed Natural Gas) –
with a tax incentive of about one Euro per kilogram
until 2018.
One technological obstacle blocks the way. In
order to make natural gas “tank friendly”, it must be
heavily compressed - which requires greater technical effort and expense, both in the refueling stations
as well as in the cars. “At natural gas stations with
pressures of 300 bar, the physical characteristics
emerge that differ greatly from normal gas stations.
You have to master this technology. That is why
we support major car manufacturers in automobile
development,” explains Dirk Rose, sales manager of
Schwelm Anlagentechnik GmbH.
Having constructed over 400 CNG stations, the
plant engineering company in the southern Ruhr
region has produced almost half of all natural gas stations in Germany, as well as building stations abroad.
The company assembles gas pumps through which
the gas flows into the gas tank of the car, as well as
compressor stations in which the gas received from
the supply lines is compressed to the necessary
pressure of 280 bar. Depending on the desired fueling output, Schwelm Anlagentechnik is also installing
47
Intrinsically safe isolating amplifiers transmit the signals
from the pressure sensors to the control unit
Up to four compressors compress the natural gas
to the necessary 280 bar in several stages
up to four compressors and up to 48 gas storage
bottles in concrete or steel sheet containers.
In the accessible compressor stations, the natural
gas is dried, cleansed, and compressed in up to four
stages from low supply pressure to tank pressure,
then stored in the gas bottles. “From the change in
state, drying and absorption to compression, a compressor station combines almost everything that the
processing technology has to offer. This makes the
natural gas stations more complicated than simple
gas tanks,” says Rose.
The pressure must be right
The natural gas pressure is decisive for the functioning of the fueling system. While gasoline and diesel
powered cars are filled using pumps, natural gas
is transported into the vehicle's tank solely by the
pressure difference from gas storage. The interplay
between the electronically controlled compressors
and three separate gas storage tanks monitored by
sensors that deliver sequentially the right filling presmore @
1_2009
sure, ensures that the station functions just as reliably and efficiently at a lower capacity as it does with
a higher fueling frequency.
This is where the interface solutions from Turck,
the sensor, fieldbus and connectivity specialist,
come into play. Operated via a single-channel HART
transducer/isolating amplifier (IM33-12EX-HI), five
switching amplifiers from the IM1-22Ex product line
ensure, per compressor, the reliable and safe transmission of sensor signals from the explosion-risk
area of the compressor stations to the control unit.
The ATEXZone2 -authorized DIN rail interfaces from
Turck allow users to adjust the effective direction
(working or standby current), as well as broken-wire
and short-circuit monitoring separately via six frontend switches. The dual-channel design also offers
the plant construction company and operators the
opportunity to transmit the analog sensor signal to
the control unit via the galvanically separated outputs and, simultaneously, to record the process data
of the storage pressures on the second channel.
This means that a redundant safety concept can be
implemented that also allows pressure and process
monitoring even in case of a short circuit.
The intrinsically safe input circuits can be monitored separately thanks to front-end LEDs: For activated input circuit monitoring, the LEDs display the
switching status in yellow. If, for example, an error
arises due to a broken wire, the respective LED
turns red. This is an enormous advantage because:
“If an error actually does exist, the first level service
must go directly to the compressor station. Remote
control alone is not possible in these safety-relevant
applications,” explains Rose.
In the compressor stations, Turck technology
not only ensures safe and reliable signal transmission
from the explosion-risk area, but also a total of four
IM interfaces are used in the natural gas fuel pumps,
in addition to two isolating amplifiers from the MK
product line. The demands in the functionality of the
devices are just as high here because “if the electronic components that are installed in fuel pumps
distributed all across Germany malfunction, the
expenditure would be many times higher than the
price of the device,” says Rose. “Several years ago,
we intensified our cooperative partnership with Turck
and have been very satisfied so far. We have not yet
had any malfunctions. When it came to the configuration of the interfaces as well as consulting services,
Turck was simply the best fit for our concept.” N

 Quick read
In Germany, environmentally conscientious and
price-conscious drivers can fill their tanks with
inexpensive natural gas at more than 400 natural gas stations built by Schwelm Anlagentechnik
GmbH. To ensure that the fuel always flows reliably,
the company installs isolating amplifiers, limit value
control gauges, and transducers from Turck.
“
Several years ago,
we intensified our
cooperative partnership with Turck
and have been very
satisfied so far. We
have not yet had any
malfunctions. When it
came to the configuration of the interfaces as
well as the consulting
services, Turck was
simply the best fit for
our concept.
”
Dirk Rose,
Schwelm Anlagentechnik
48 A P P L I C AT I O N S _ I N T E R FA C E
TECHNOLOGY
Author
Holger Anders is a
key account manager
process automation
at Turck Germany
in Mülheim
Webcode | more20958e
Infraserv Höchst
supplies around 90
companies from the
pharmaceutical,
chemical and biotechnological industries
in the industrial park
with water, energy,
and media
Water for Höchst
Even when it comes to expansions, facility operator Infraserv relies on the
19-inch interface technology from Turck for water treatment
W
ithout water, not much happens in
the Höchst industrial park: Whether
an urgently required solvent for
chemical and pharmaceutical processes or as a
medium for cooling processes, water is of fundamental importance for the research and production
facility in Frankfurt, Germany. Around 400 million
cubic meters of water are used annually in the
Höchst industrial park: this is the equivalent of about
ten times the amount of annual drinking water for the
city of Frankfurt.
So it is a distinct advantage that the industrial
park is located directly on the banks of the Main
River. About 99 percent of the park's water demand
is supplied by water from the Main River and is, in
part, specially treated and reused multiple times.
Only about one percent of the water comes from
ground water. Infraserv Höchst supplies water to the
N
 Quick read
Continual monitoring and forwarding must be performed via 4,000
measuring points so that an annual amount of 400 million cubic meters
of water is treated and distributed throughout the Höchst industrial park
smoothly. The operator of the industrial park, Infraserv Höchst, relies
primarily on 19-inch interface technology.
approximately 90 companies in the pharmaceutical, chemical, and biotechnology industries that are
located in the Höchst industrial park. About 22,000
people work on the 460 hectar grounds of the industrial park. Of these 1,900 employees and 121 trainees work for Infraserv Höchst.
Infraserv Höchst also supplies the companies
at the industrial park with power and media, it provides waste disposal services and makes demanding technical infrastructures available. Water supply, treatment, and distribution is handled by the
Energies business field. This includes a power
generation plant for purified water and its associated distribution system for the pharmaceutical
companies. With its guaranteed generation capacity of 240 m3/h and 14 km of pipelines, Infraserv
Höchst's the generation and distribution system
is the largest of its kind worldwide and implements the most state-of-the art production and
manufacturing technologies.
“We have a total of over 4,000 measuring
points for binary and analog signals in the field of
water treatment,” says Michael Pauly, responsible
for the maintenance of the electrical, measurement
and instrumentation technology (EMR) in the field
of water treatment. Infraserv Höchst uses analog
signal separators from Turck to adapt and galvanically separate the analog signals, such as pressure
49
“
We have all kinds
of different suppliers
here in the industrial
park – so of course
we shopped around
on the market. Yet, in
the cost/benefit ratio,
Turck came out the
clear winner.
”
Michael Pauly,
Infraserv
values, quantities, filling levels and pH values, and
then bring them “cleanly” into the process control system. The engineers at Infraserv Höchst are
building on the 19-inch technology that was established as the industry standard ten years ago. While
many manufacturers of 19-inch technology have
increasingly migrated to DIN rail devices, Turck will
continue to offer modern interface technology in all
configurations – from the cartridge to the DIN rail
devices to 19-inch insert cards.
“In my opinion, the 19-inch technology is cleaner
in terms of its configuration. Especially if you already
have a rack and want to add something to it,” says
Pauly in explaining the decision for the insert cards.
“Even if I have firm requirements on where the
inputs and outputs lie, integration is still easy. Naturally, there is also a bit of a sense of tradition here.”
Turck guarantees that this tradition can be continued thanks to its long-term support and further
development of this configuration. “This is an important argument for Infraserv Höchst to use interface
technology from Turck, because future expansions
would also be planned for in 19-inch technology,”
says Pauly. “We have all kinds of different suppliers
here in the industrial park – so of course we shopped
around on the market. Yet, in the cost/benefit
ratio, Turck came out the clear winner.”
Filling level measurement
per ultrasound
Turck not only delivers interface technology to
Infraserv Höchst, some of the signals that run along
the analog signal separators come from Turck or
Banner devices. This includes ultrasound sensors
to monitor the filling level of the additives, which are
required for water treatment. The sensors have a
PNP transistor output and an analog output for voltage and the measurement range is adjustable via
teach-in. The sensors are easily operated via teachin which was another factor that tipped the balance
in Turck's favor. N
Ultrasound sensors
from the type Banner
T30UUPBQ monitor
the filling level of the
additives, which are
required for water
treatment
Infraserv Höchst uses interface technology in the
19-inch format for numerous measurements
more @
1_2009
50 A P P L I C AT I O N S _ I N T E R FA C E
Author
Pavel Fateev is the
managing director
of Turck Russia
in Moscow
Webcode | more20959e
Safety in the control
cabinet – proven interface
technology from Turck
provides excellent
reliability at OAO
SpecElectroMechanika
TECHNOLOGY
51
Black Gold –
Yellow Technology
Measuring amplifiers from Turck guarantee reliable monitoring of the oil
temperatures at Russia’s largest sea port
R
ussia is not only the biggest country on
Earth, it is the second largest oil producer
worldwide after Saudi Arabia. Russia produces nearly ten million barrels of black gold a day,
and turnover remains very high despite the current
oil price between $40 and $50 per barrel. However,
before the oil generates a profit, it has to be transported from the wellheads to one of Russia’s many
refineries or to an industrial port for shipment to Germany, the Czech Republic, China and many other
countries.
One of the winners on the huge Russian oil market is OAO SpecElectroMechanika. The company is
one of the leading Russian players in the automation
sector, and it delivers factory automation solutions for
the entire production chain in the oil industry, including the pre-processing, transportation and refining of
this valuable resource. For more than ten years, the
company, which is based in the Krasnodar region,
has been producing and supplying machinery and
components used to automate complex, rugged
oil processing and transportation equipment. The

 Quick read
The demand for oil has never been higher – regardless whether it is used
for light heating oil or as a lubricant. The Russian supplier SpecElectroMechanika relies on Turck interface technology for its automation systems to ensure that the black gold can be safely loaded onto tankers at
the huge oil terminal in Novorossiysk, Russia’s largest sea port.
company’s portfolio includes microprocessor components, blackbox control stations, as well as automated pressure and temperature control systems.
Because handling black gold can be very profitable,
but also very dangerous, the components that the
company builds into its automation solutions have
to meet very stringent requirements. “Our overall
quality standards are always very demanding,” says
Alexey Krasyuk, chief engineer at OAO SpecElectroMechanika. “Therefore, we try to source the components for our products exclusively from leading
manufacturers.”
Oil is loaded onto
huge tankers at the
Russian port of
Novorossiysk –
automated processing and transport
systems guarantee
the required safety
more @
1_2009
52
A P P L I C AT I O N S _ I N T E R FA C E T E C H N O L O G Y
3 or 4 wire, 1-channel measuring amplifiers also offer
users extensive diagnostic, monitoring and parameterization features. For example, a switch on the front
panel activates wire break detection on the input circuit. With a single switch, the user can set parameters that define current output characteristics when
an error is detected in the input circuit.
If input circuit error detection is turned on, the
output current is either 0 mA or 22 mA, and a red
LED is switched on to indicate the fault condition. If
input circuit error detection is deactivated, the output
signal tracks the direction of the input signal (0 mA if
a wire breaks, 22 mA if a short circuit occurs).
Reliable and functional
Turck interfaces are easy to install on DIN rails
Temperature is decisive
“
Even six years
down the road,
we are still impressed
by the quality,
stability, and high
functionality of Turck
products. MK series
interface modules
significantly enhance
machine reliability and
make our machines
more user friendly.
”
Alexey Krasyuk, OAO
SpecElectroMechanika
Correct temperature is one of the most important
process parameters during the production and transportation of this precious resource. When crude oil is
converted to feedstock and then refined to produce
marketable fuels, heating oil and lubricants, it must
be kept at the right temperature at all times during
the various production, processing and transportation steps.
SpecElectroMechanika has integrated Turck
interface technology into its automation solutions to
continuously monitor the temperature of the oil, even
when the oil is not going through one of the refinery processes. MK32 measuring amplifiers monitor
the input signals of the Pt100 temperature control
sensors on the oil tanks in the huge oil terminal at
Russia’s largest seaport in Novorossiysk. In this
Black Sea port located in the Krasnodar region at
the northwest end of the Caucasus, petroleum and
petroleum products brought in by train are loaded
onto ships every day. These ships have a loading
capacity of up to 15,000 DWT. The machinery has
to be very rugged to withstand the industrial environment at the port. The partially automated systems
must be immune to dust, oil, water, vibration and
even impact.
Intrinsically safe MK32 measuring amplifiers with
galvanic isolation between the input and output circuits reliably detect temperature-related changes
in resistance in the Pt100 sensors. The subsystem
operates safely in hazardous areas and sends an
analog output signal to a higher level controller. The
Turck components guarantee the necessary operational reliability in hazardous areas, while also offering excellent functionality. “Even six years down the
road, we are still impressed by the quality, stability,
and high functionality of Turck products. MK series
interface modules significantly enhance machine reliability and make our machines more user friendly,”
explained Krasyuk.
Turck products are very reliable, and they cover
a wide measurement range between –50 °C and
+600 °C, enabling engineers at SpecElectroMechanika and oil terminal owners to reduce the
installation and maintenance costs of the automation
solutions. “We were particularly impressed with the
good, collaborative relationship with Turck. The interface specialists deliver high quality at a reasonable
price with short lead times,” said Krasyuk.
Another thing the automation supplier from Russia appreciates is that the MK interfaces are easy
to install on a DIN C rail, which has shortened the
installation time considerably and increased machine
availability. 

 Temperature sensing with the Pt100
Pt100 probes are the core element of reliable sensors that come into contact with
the media. The measurement sensors have
a nominal resistance of 100 ohms. They are
based on changing resistance in a platinum
wire or platinum layer as the temperature
changes (DIN IEC 60751). During operation,
the voltage drop is measured at the sensor,
while the current flow through the sensor is
held constant. The Turck 1-channel MK32
measuring amplifier senses the resistance
changes in the Pt100 probes and sends temperature linear current signals to a higher level
controller. Only a few switches are needed to
set up the intrinsically safe switches for operation in the temperature range between -50 °C
and +600 °C. The amplifiers offer a selection
of input circuit monitoring functions.
UDCU ICAT SD ATA
O P 5353
S E R V I C EF
_ PI D
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Product Data on DVD
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Regardless of what information source you use, the Turck
product database on DVD or on
the Internet will provide comprehensive information material
focusing on Turck solutions for
plant and process automation.
There you can find data sheets,
brochures, catalogs, and even
software. Different search functions will help you find the right
solution for your automation
needs.
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54 A P P L I C AT I O N S _ C O N N E C T I O N / F I E L D B U S
TECHNOLOGY
Flexible Production
US manufacturer Genentech relies on rugged connection and fieldbus
solutions from Turck
T
he United States pharmaceutical industry is rife with change. Plans to develop a
new biotechnology facility that produces
the cancer fighting drug Avastin resulted in five years
of development, two years of construction and three
changes of ownership. In the end, none of these
aspects halted what would become Genentech, Inc.’s,
www.gene.com, New IDEC Manufacturing Operations (NIMO) plant in Oceanside, California, located
about 35 miles north of San Diego.
A team of engineers, architects and a general
contractor began designing the Oceanside facility
early in the decade, and coined a new “design-build
hybrid” approach that implemented unique manufacturing innovations, design advancements and quality
contributions to the facility.
One of the innovations, the use of fieldbus technology, was considered a breakthrough for the pharmaceutical industry at that time. “Before the Oceanside facility, it was unheard of for a biotech/pharma
plant to have a significant amount of bus,” said Denise
Kresge with CRB Consulting Engineers, Inc., the
engineering firm selected for the overall facility and
manufacturing process design. “Now, that plant has
become a template for almost every grassroots pharmaceutical plant CRB has been involved with in the
last few years.”
According to Kresge, there was considerable
concern about gaining (Food and Drug Administra-
Author
David Fazzini is the
global director for
the pharmaceutical
industry at Turck
USA in Minneapolis
Webcode | more20960e
The connection and
fieldbus technology
from Turck withstands
the hard wash-down
conditions in the
Genentech plant
tion) FDA approval: “This concept presented certain
challenges from a design perspective. One challenge
was to install the cable to meet sanitation requirements and withstand the frequent washdowns in the
cleanroom environment. Another was to prevent the
induction of outside noise from the power supply and
production equipment. The communication cables
had to be shielded, and we had to follow the separation rules for cable assembly and installation.” The
Oceanside facility received FDA approval in 2006.
Subassemblies Lead to Efficiency
The 210,000 square-foot production area was one of
the first biotech manufacturing facilities to successfully utilize large modular super skids built offsite and
shipped to the plant. More than 70 process tanks and
18 fermenters were integrated into 17 large modules.
This approach saved time on the original construction
and reduced on-site labor.
All of the modules were built using Turck wiring
systems before they were shipped to the Oceanside
location. Segments were applied to 48 control panels
that used DeltaV control, and included a minimum of
two Foundation Fieldbus and DeviceNet segments per
panel. The segments used Turck Foundation Fieldbus
and DeviceNet quick-disconnect ITC (instrumentation
tray cables) cables to connect approximately 95 percent of the automation instruments to the distributed
55
control system. Not only was wiring with ITC cables
faster than wiring with conduit, it also consumes less
space to run the amount of I/O required by the plant.
Two Turck DeviceNet advanced I/O module (AIM)
remote I/O stations were also used within the panel.
AIM stations and Foundation Fieldbus junction bricks
were mounted on the process equipment and connected to the networks in the panel. AIM stations can
accept 16 discrete I/O points, and each DeviceNet
segment supported up to 63 AIM stations. Many of
the segments did not fully utilize the maximum I/O
capacity to allow room for expansions. The FF junction bricks can accept 10 to 12 analog instruments
or valve controllers per segment.
The decision to use a standard panel design
resulted in lower construction costs and easier panel
fabrication. The implementation of both DeviceNet
and Foundation Fieldbus technology reduced the
amount of wiring required for commissioning and subsequently reduced panel size and cost. Conducting
the wiring in the fabrication shop minimized the wiring
that had to take place in the plant and greatly reduced
construction and start-up time. Another advantage
of using Foundation Fieldbus is faster commissioning
due to the asset management tools that are available
with this system.
Today, the NIMO plant has more than 16,000
instruments, including 7,291 Foundation Fieldbus
and 1,230 DeviceNet devices, including Turck’s AIM
stations. Because Turck products meet IP67 environmental protection standards, they don’t need to be
enclosed in water-resistant cabinets for washdown
environments, another important consideration in
pharmaceutical construction.
The choice to use Turck connectivity products in
the initial design paid off during construction and commissioning, as well as three subsequent plant modifi-
cations, when the facility changed ownership and had
to be altered to accommodate a totally different product in 2003 and in 2005. The aggressive schedule and
limited budget would have been significant issues with
a traditional hardwired control system, but the flexibility of the ITC cables and quick-disconnect solution
allowed the changes to be completed on time.
“For the first modification, we simply relocated
instruments as required by the new process using
existing distribution grids and trunk lines. Disconnecting and reconnecting cables was easy. Rewiring
would have been much more expensive. The cost
was appreciably lower, and the results are first-class,”
said Joe Hohn, Control Systems Engineer with Dynalectric, the instrument and controls (I&C) contractor.
“Errors that remain undetected until commissioning can be very expensive,” Hohn explained. “We try
to protect ourselves by specifying the highest quality products that promise lower installed costs.” The
quality of the Turck cables was a major factor in the
significantly faster initial commissioning of the NIMO
facility, since there were no unexpected delays due to
faulty connectors or underperforming cables.
“Installed cost is the most important factor for a
turnkey contractor like us,” continues Hohn, “There
are other factors, of course, but the control network
installation and commissioning are so much faster
and easier with Turck cables that the final cost of the
system was dramatically lower. Compared with conventional wiring on a big project like this, the installed
cost, including commissioning, is on the order of onesixth as much.” Even more impressive is the fact that
Dynalectric technical personnel have yet to encounter
a quality problem with Turck products. “I don’t know
what their quality assurance program is like where
they assemble these products,” Hohn said, “but we
see nothing but 100 percent quality.” N
“
I don’t know what
their quality assurance program is like
where they assemble
these products, but
we see nothing but
100 percent quality.
„
Joe Hohn,
Dynalectric

 Quick read
More than 16,000 I/O signals are received at the
Biotech plant of Genentech, Inc. in Oceanside,
California, and forwarded to the control system.
Because the connection solutions themselves
have to function reliably in raw “wash-down” environments, the pharmaceutical producer trusts the
IP67-certified fieldbus cable, DeviceNet blockmodules and distributor components from Turck.
More than 90
percent of the
components
were connected
to the control
system using
ready-made
fieldbus cables
and plug-in
connectors
from Turck
more @
1_2009
56 I N S I D E _ E s c h a
TsL
Author
Marco Stapelmann
is an editor at
Turck Germany
in Mülheim
Webcode | more20931e
More than one
million short stroke
push buttons with
atmospheric pressure
equalization system –
called Escha button for
short – are in operation
around the world
Touch Me
Around the world, innovative pushbuttons and LED lights from Escha
TSL are opening doors for public transportion
57
In trains and buses, you can't walk down an aisle without passing an Escha TSL product – the product line of
the Turck subsidiary ranges from door-opening buttons to warning and safety lighting and hand pole buttons
E
ven if you've never heard of a presskey,
combikey or an MP30 timer button before,
chances are if you've ever used public transport, you have pressed one at one time or
another. These short stroke pushbuttons are simply
called Escha buttons. They are primarily used as
door-opening buttons in street cars and rail cars, but
they are also used as operating elements for sinks
and toilets, or as combined audio-visual signal devices. Escha TSL GmbH, located in the city of Halver in
the German state of Sauerland, develops and manufactures these products found everywhere in public
mainline and commuter rail systems.
As a market leader in the area of pushbutton
and switching technology, this member of the Turck
Group has produced the majority of door-opening
buttons used in Germany, as well as manufacturing custom-made switches and LED solutions for
Europe, America, India and New Zealand. “About 99
percent of all buttons used in the rail cars of Deutsche
Bahn come from Escha TSL,” explains Klaus-Peter
Schmauch, the company's technical director. “Our
market share in Europe is about 40 percent.”
In order to be able to offer overseas customers
innovative buttons, switches and LED solutions, the

 Quick read
Starting with the presskey door-opening buttons
in 1986, Escha TSL is today the market leader
in button and switch technology in buses and
rail cars. Regardless of whether it's door openers in the trains of the Deutsche Bahn, hand
pole buttons in buses or industrial LED lighting
solutions – customers worldwide use the products from the specialist for buttons, switches,
and lights. The factors of success include easy
operation and durability.
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1_2009
Success at the
button: Lutz
Höfer, general
manager (l.), and
Klaus-Peter
Schmauch, technical director at
Escha TSL
Turck subsidiary often uses established Turck sales
channels, such as in Poland, Romania, and Belgium.
Escha TSL is building up its own sales structures
in the most important industrial nations, especially
for the rapidly growing Chinese market. The company has founded its own production facility near the
Turck Tianjin Technology company, which produces
Turck products for the Asian market.
First product launched in 1986
Two employees from the switching technology division of Escha Bauelemente GmbH laid the cornerstone for this success in 1986 with the development
of the press key. With more than one million units
sold, it is still the most successful and important
product in the Escha TSL portfolio. The innovative short stroke push button for inside and outside
doors scored points due to its flexibility with regard
to design and built-in atmospheric pressure equalization system. The Escha button quickly established
58 I nside _ E s c h a
Escha TSL buttons
also open doors of
this Alstom-Bombardier street car
in Gera, Germany
“
About 99 percent
of all buttons used
in the rail cars of the
Deutsche Bahn come
from Escha TSL.
Our market share in
Europe is about
40 percent.
”
Klaus-Peter Schmauch,
Escha TSL
TSL
itself as a high quality and durable switching solution. A small silicon hose integrated into the switching mechanism – not much thicker than a pencil
lead – ensures that the air-tight sealed electronic
components function reliably even at temperature
or altitude-related exterior pressure changes. The
key: The physically simple principle guarantees
not only that the button functions smoothly under
extreme temperatures of -40 to +80 °C, but also
guarantees a steady and continuous actuating
force. This development literally opened the doors
for the switch specialists from Germany to applications exposed to extreme temperatures, such as in
Scandinavia.
Business with the door-opening buttons was
so successful that management at Escha Bauelemente GmbH decided to establish an independent
company, Escha TSL GmbH, for this product line in
2006. A decision that paid off for both the company
and the customers. “As a medium-sized company,
we are able to offer extreme flexibility and provide
solutions even for more complex applications within
just a few weeks,” says Lutz Höfer, General Manager
at Escha TSL. “And even if we had to learn Chinese
for a customer within two weeks, we would manage
that too,” adds Schmauch with a smile.
Using all senses
With 29 employees in Halver and additional employees in overseas sales offices, the company's core
competence is to develop and produce easy-tooperate pushbuttons and switches for the handicapped. “A major issue for them is barrier-free public
transport,” explains Schmauch. “Our products are
therefore completely geared toward optimal operability. They allow people with physical handicaps
to actuate buttons and switches using different
senses.”
In the meantime, Escha TSL provides its customers
with 15 different design configurations of the press
key with numerous pictograms and labels for the
best possible operability in every day use – regardless of whether it says “please press” in the local
public buses or “push here” in public restrooms or
“door open” in American street cars. The compact
minipress switch, the combikey with integrated
sounds for actuating the switch and different signal
lights for filling level displays, and safety lighting have
been added to the portfolio.
The service offerings range from development
and construction, to tool and prototype design, to
the serial production of switch and lighting solutions –
including ready-made connection options. Above all,
the modern LED technology and the industrial lighting and signal equipment are an increasingly important business division for the button, switch and
lighting experts from Halver. “We offer our customers
20 years of experience in dealing with LED technology. You cannot achieve the long service life of our
rugged lighting solutions using inexpensive products
from the home improvement store,” says Höfer.
59
The silicon hose
of the press key
compensates for
pressure fluctuations and protects
against vandalism
and malfunctions in
the button
Strong together
Regardless of whether it's industrial LED lights or a
comprehensive product line of buttons and switches, Escha TSL has been supplying its customers
exclusively with handcrafted quality “made in Germany” products since day one. Here, the company
has benefited from its proximity to Escha and Turck.
While Escha Bauelemente GmbH supplies the housing for the rugged IP67 switches and signal units,
Turck contributes to the development, and produces the built-in switching electronics. “Therefore,
Turck quality is also hidden in each Escha button,”
summarizes Höfer. “When synergies can be taken
advantage of, the people at Escha TSL are open to
many ideas. That is why we are working on a current
project, for example, to use the sensor housing from
Turck as the housing for special LED lighting.”
Thanks to this cooperation, Escha TSL can
concentrate entirely on the final assembly of its high
quality products in its own production halls. The production department manned by 15 employees can
produce customer-specific product solutions quickly
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1_2009
and flexibly with batch sizes from several dozen up
to several hundred units with the help of vertical integration and some automation.
Reliability over the decades
The production quality achieved through electronics, housing and tool know-how has paid off both
for Escha TSL, as well as for customers all around
the world. Following the standards concerning reliability of the button and switch solutions used in
public transport, more and more customers want a
guarantee for the durability of their products. “Our
products function so reliably that one customer has
already signed a subsequent delivery order with us
for the year 2018,” mentions Höfer.
Innovative products, flexibility and customer proximity are the success factors that have made Escha
TSL the market leader among rail and bus companies.
Management is therefore confronting the current economic crisis with a somewhat relaxed attitude. “We
achieved sales growth of 30 percent in 2008 and are
expecting additional growth in 2009,” says Höfer. N
Made in Germany:
Handmade products with CAD support permits individual solutions
60 T E C H N O L O G Y _ B L 2 0
HART MODULES
Author
Phil Whorton is the
product manager of
fieldbus technology
at Turck Germany
in Mülheim
Webcode | more20971e
With the new Hart
modules, BL20 users
can transmit, in addition
to the analog signal,
other digital measurement and diagnosis
data from the field,
even up to Zone 2
It is Hart
Turck expands functionality and fields of
application for the BL20 fieldbus system
with Hart-compatible I/O modules
A
lthough the Hart (Highway Addressable
Remote Transducer) communications
protocol has been around for almost 20
years, use of this communication solution for the
“last mile” to the field devices in process automation
is still wide-spread. Turck is therefore expanding its
modular BL20 remote I/O system by adding new
61
Based on the
FDT/DTM technology, analog field
devices can be
managed efficiently
via free basic applications such as
PACTware
Hart-compatible analog cards. The dual-channel
input/output modules allow users to easily connect
their analog field devices to the process control
system via the universal bus terminal system and
integrate into a continuous asset management concept based on FDT/DTM technology. The key: Digital and analog communication can be performed
via Hart and using existing 4 to 2 0 mA wiring.
By adding analog Hart modules to its fieldbus
system, Turck is responding to the huge demand
for efficient I/O solutions for analog instrumentation in processing technology. The Hart-compatible
modules make it possible to transmit additional
values or diagnostic data interference-free from
the field via the modulated digital signal, regardless
of whether valve drives are going to be integrated
into remote maintenance devices or additional temperature data is recorded. The BL20 system can
be used almost anywhere, from non-explosion risk
areas to Atex Zone 2.
Interactive communication
The advantages of Hart communication are widespread. Because the communications protocol
makes data transmission possible via existing pipe
installations, users can expand and maintain the
“last mile” with little expense. Additionally, the modulated digital signal in the “Frequency Shift Keying”
process (FSK) does not influence the actual analog
signal, so that interference-free interactive communication between the process automation system and analog field devices can be established by
combining both transmission types.
The new analog cards offer the same benefits as
other Turck BL20 components. All electronic modules can be simply plugged into the passive basic
modules on the BL20 system – up to 72 expansion modules can be added on a single system. To
connect the fieldbus to the entire station, different
gateways for Profibus DP, Profinet, Modbus TCP or
Ethernet/IP are available in standard or economy
models, as well as CoDeSys programmable gateways for Ethernet connections.
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BL20 users have the choice between basic modules
with tension springs or screw connection technology – simplifiying the handling of the IP20 fieldbus
system in case of maintenance. Up to two adjacent electronic modules can be replaced – even
during continuous operation in the remote I/O
station.
To integrate the new analog cards in the BL20
field nodes, users can utilize Turck's free I/O assistant software. The modular project planning software
supplies important information on the necessary
electronics components, ranging from type labels
to order numbers. Moreover, users can graphically
display their fieldbus solutions and rely directly on
dimensioned drawings or parameter lists, which
considerably reduces order picking time.
Comfortable diagnostics
Hart modules and project planning software also
support standardized FDT/DTM technology. The
parameters of the connected field devices can be
simply and transparently visualized and configured
in a manufacturer-independent engineering tool (like
PACTware). Users can diagnose and parameterize
the field devices using the basic application without
having to grapple with the incompatibilities between
different device drivers.
The status LEDs located directly on the electronic modules are a new feature in the software
diagnosis options. They help the maintenance personnel easily identify the status of module communication at a glance. 

 Quick read
Thanks to the new Hart-compatible electronic modules, Turck has
expanded the areas of application for its BL20 modular fieldbus system.
With FDT/DTM support, users can integrate their analog field devices
efficiently into a continuous asset management system using the remote
I/O system. The key: BL20 can be used in almost all areas of process
engineering, even Atex Zone 2.
62 T E C H N O L O G Y _ P R O F I B U S
DIAGNOSTICS
Author
Peter Praske is a
fieldbus consultant
for process
automation at
Turck Germany
in Mülheim
Webcode | more20972e
Vertical continuity
between the office
and field devices:
As a web server,
the PB-XEPI opens up
Profibus networks for
remote maintenance
and diagnosis via
the Internet
Bus Diagnostics
Turck's Ethernet Profibus interface PB-XEPI monitors fieldbus communication and
opens Profibus networks for remote monitoring and diagnostics via the Internet
T
he new Ethernet Profibus coupler, PBXEPI, enables vertical continuity in communicating between the office and the
field devices. Thanks to the intelligent interfaces,
plant operators can monitor and set the parameters
of their Profibus subscribers, as well as all connected
field devices, centrally and independently from the
control system via a computer web browser. The
interfaces are easy to integrate into new or existing
fieldbus structures, and thereby make an important
contribution to continuous asset management and
maintenance concepts.
The diagnostics unit acts as a web server, and
enables users to monitor a large number of Profibus
networks in parallel and continuously during ongoing operation for the first time ever. Due to system-
independent Ethernet communication and licensefree software, the instrumentation on the machines
and their quantity do not matter. The interfaces are
simply integrated vertically into the Profibus networks to be monitored. Using the Ethernet protocol, they establish a communications and diagnostic
infrastructure and open all integrated fieldbus networks for remote maintenance via a computer web
browser.
Access via a web browser
The PB-XEPI gives technicians, machine and plant
builders, along with external service suppliers, the
option of reacting quickly to fieldbus disruptions and
disruptions experienced by connected subscrib-
63
ers at any time without having to rely on proprietary
engineering tools. Single requirement: Access to the
Internet.
The PB-XEPI can be used as a diagnostics unit
for different monitoring or configuration applications. As a pure listener without a separate Profibus
address, the interface monitors the data flow of the
fieldbus network without participating in communication. In this configuration, the diagnostics unit
independently identifies the disruptions occurring in
the Profibus network and, in case of a malfunction,
sends out an error message via e-mail.
The error message may be retrieved from any
location – from the centralized maintenance department on site, via a remote service computer or using
a mobile cell phone. A link included in the message
allows users to access the respective diagnostics
unit directly and recall detailed information and a
recommended course of action. All monitoring and
alarm settings can be adjusted easily using a web
browser – special client software or licenses are not
required. The diagnostic information can also be
integrated into third-party applications via the web.
Expanded diagnostic functions
The intelligent Ethernet Profibus interface can also
be configured as an active network subscriber. As a
Master Class 2 with an independent station address,
the PB-XEPI allows the configuration and diagnosis of the Profibus network by using FDT/DTM and
OPC. The software package Profibus Scope 4.0,
TH OPC server DP and AMS Suite supplement the
integrated diagnostic options of the PB-XEPI by
adding analysis functions for more complex error
searches or expanded asset management functionalities, such as recording operating hours. Thanks to
the graphic user interfaces and transparent window
technology, users receive all relevant information on
the state of the network in real time.
As a central bus access via the Ethernet interface,
the PB-XEPI also supports the manufacturer-independent quasi standard FDT/DTM. The advantage of this combination of license-free framework
application and driver software is that the relevant
parameterizing and diagnostic data of the connected
field devices can be simply managed and visualized
based on the “driver files” - the device type man-

 Quick read
The new diagnosis interface PB-XEPI enables users to continually monitor their Profibus networks, clearly identify occurring problems and react
quickly and purposefully via remote maintenance using a web browser.
The interface is easy to integrate into fieldbus networks.
agers (DTM). The user no longer has to deal with
managing the diagnostic data or the incompatibility
of different diagnostic tools. Instead, users can concentrate entirely on the content of the data received,
and thereby on the plant status.
Turck offers its customers both the higher-level
framework application PACTware 3.6, as well as the
communications DTM, for the diagnostics unit for
free download.
Summary
Based on integrated diagnostic functions and additionally available analysis and parameterizing tools
for all traditional standards, such as FDT/DTM, OPC
and EDD, PB-XEPI, it is easy to get started in continuous asset management and maintenance concepts
by providing universal Profibus access. The simple
installation and operation, as well as the option of
expanding the diagnostic infrastructure through
additional interfaces, makes the PB-XEPI a solution
for the most varying Profibus diagnosis scenarios. N
Status report in
the browser: The
web server of the
PB-XEPI permits
network diagnosis
and access via
the Internet
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1_2009
64 T E C H N O L O G Y _ B A S I C S
Author
Klaus Ebinger is the
product manager
for process sensors
at Turck Germany
in Mülheim
Webcode | more20973e
Straight from the Turck
research laboratory:
The fully encapsulated
pressure sensor PS300
How Pressure
Sensors Function…
Part 5 of our basic series on the design,
functional principles and application options of
the most important sensor technologies
R
egardless of whether you are driving
a car or riding in an airplane, pressure
information is part of our daily routine.
At the same time, pressure is elusive because a
pressure value always refers to a certain reference.
A positive and negative overpressure measurement
reflects the difference in the measured pressure
compared to the respective atmospheric pressure.
Therefore, most measurement devices must have
an open reference connection to the atmosphere.
This type of pressure is referred to as relative pressure, overpressure or gauge pressure, though they
all have the same meaning.
If higher pressures – starting at about 50 bar –
are measured, the measurement devices are also
found with a closed reference connection, known
as gauge sensors (closed overpressure). At these
high pressures, the relatively low fluctuations in the
atmospheric pressure do not influence the accuracy of the measured value.
Absolute pressure, on the other hand, refers
to airless space, meaning the vacuum. In practice,
you evacuate the reference side of the respective
measuring device and seal it off so it is air tight.
The degree of the vacuum generated is decisive for
the quality of the measurement. Meteorologists, for
example, require absolute pressures for preparing
daily weather forecasts. In the industry, the pressure and temperature compensation of gases is
one of the main areas of application for this type
of measurement.
With differential pressure, the process
pressure is created on the reference side of
the device. This enables container filling
levels, flow rates and leakages in the systems to be defined. When measuring the
flow rate using pressure as a measurement variable, you have to know that the
differential pressure on a defined restriction acts proportionally to the flow rate
speed of the medium. Occasionally, the
differential pressure can be very small
in contrast to the adjacent static pressure in the piping.
Making pressure visible
Pressure can be recorded by the most
varying kinds of measuring devices.
Most pressure sensors convert the measured pressure into a deformation force. In contrast to inductive or capacitive proximity switches, the pressure
value should also be frequently displayed or converted into an analog output signal. With pressure
sensing, the measured value is normally disrupted
only by temperature influences – the measurement
is completely unaffected by density, viscosity or
chemical properties.
In general, a distinction can be made between
two types of measurements: Direct and indirect
measurement systems. The first refer to the physical foundation of the pressure (force per surface).
65
Pressure compensators, U-tube and inclined tube
manometers work according to this principle; all
mobile equipment that is used in lab applications.
Only a few doctors still use the mercury column for
determining blood pressure (unit: mmHg). Pressure
compensators are used as primary standards in
many accredited test labs. Although they are considered as unusually durable, precise and reliable, these
devices have almost completely disappeared from
the industrial sector.
An entirely different measuring principle is behind
the indirect pressure measurements. In order to generate a signal proportional to pressure, these devices rely on different physical effects. They convert
the effect of the pressure directly into a motion and
supply this to the display. This can be done either
with a pipe or a diaphragm pressure gauge. Thus,
manometers rank among the typical mechanical
pressure sensors that the industry still uses in many
areas, but which are being gradually replaced by
electrical measuring transducers, depending on the
application.
Even when it comes to electrical pressure measurement, manufacturers resort to the most varying
technologies in order to convert the pressure into
an electrical signal. Among the most important representative technologies are the strain gauge strips,

 Quick read
The pressure measurement plays a main role in
monitoring containers, recording filling levels or
flow rates and in many other processes. Each
individual application has its specific requirements for sensor technology. In doing so, there
is a fundamental distinction to be made between the pressure effects in liquids, gases, and
also air.
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1_2009
piezo electric, capacitive and inductive sensors or
resonators. The signals that emerge here have to
be mostly amplified and made linear. The big advantage of electrical device variants is in their extreme
precision, excellent reproducibility, and their flexible
connection options to the higher-level systems.
The Turck portfolio
Turck provides its customers with a broad array of
products and services for numerous applications in
many industries. In addition to the PK series developed with a very small housing exclusively for pneumatic and vacuum applications, Turck offers pressure
sensors for gases and liquids in four categories that
all function with a ceramic measuring cell. These
include the PS series with a robust stainless steel
housing, a four-digit, 7 segment display, as well as
different variants with switching and analog output;
the PC-M series with die-cast housing, 4-digit, 7 segment display and stainless steel connection; the PT
series with stainless steel housing and 2-wire technology with analog output and the PC series equipped
with a customer-specific switching output. Depending on the series, the precision of the sensors lies
within a range 0.3 to 2 percent from the end value.
The most recent solution from Turck developers
was unveiled for the first time at the Hanover trade
show. The PS300 is a compact pressure sensor for
hydraulic applications that is suitable for measurement ranges from -1 to 600 bar. It distinguishes itself
through high resistance to overpressure, excellent
precision of 0.3 percent, and a completely cast rugged evaluation unit. The PS300 additionally offers
three electrical outputs for all measuring ranges.
Here, too, Turck relies again on open standards. The
new pressure sensors support not only the VDMA
menu structure, but also the I/O link communications
standard. Metal-supported sealing rings ensure a
reliable process connection. N
Pressure sensors
in such a density
are not always
necessary
66
S E R V I C E _ C O N TA C T
Turck at Trade Shows
At numerous national and international trade shows, Turck will be introducing you
to current product innovations and reliable solutions for plant and process automation. Be our guest and see for yourself.
Dates
Name of Trade Show
City, Country
20.04. - 24.04.2009
22.04. - 23.04.2009
22.04. - 23.04.2009
05.05. - 07.05.2009
07.05. - 09.05.2009
11.05. - 15.05.2009
11.05. - 15.05.2009
13.05. - 16.05.2009
19.05. - 22.05.2009
26.05. - 29.05.2009
27.05. - 29.05.2008
28.05. - 30.05.2009
23.06. - 26.06.2009
23.06. - 26.06.2009
24.06. - 26.06.2009
20.08. - 23.08.2009
01.09. - 04.09.2009
11.09. - 13.09.2009
14.09. - 18.09.2009
22.09. - 24.09.2009
23.09. - 25.09.2009
28.09. - 02.10.2009
06.10. - 08.10.2009
07.10. - 09.10.2009
13.10. - 16.10.2009
14.10. - 15.10.2009
20.10. - 22.10.2009
20.10. - 23.10.2009
28.10. - 31.10.2009
03.11. - 07.11.2009
10.11. - 12.11.2009
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Imprint
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Hans Turck GmbH & Co. KG
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Editorial Staff
Klaus Albers (responsible)
Karen Keller, Marco Stapelmann
Staff involved in this edition
Holger Anders, Markus Bregulla, Marc DiSera, Klaus Ebinger, Pavel
Fateev, David Fazzini, Walter Hein, Frank Humbert, Ryan Kromhout,
Qiang Lin, Bo Liu, Shuxiang Liu, Ulf Löfqvist, Peter Praske, Dr. Ulla
Reutner, Matthias Schick, Phil Whorton, Deyou Yang
Art Direction / Graphic Design
Arno Kraemer, Britta Fehr (Art design)
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D900431
Witzlebenstraße 7
45472 Mülheim an der Ruhr
Germany
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0409
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