Issue 6 / 2013

CONNECT UK.

www.weidmuller.co.uk

CONTENTS & INTRO

VPU Surge Protection Promotion 2013 Try our online game Lightning Strike for a chance to win a Weidmller sports backpack. Play between 11 March and 15 April to win one of ten Wii U including Sports Connection. Simply go to www.varitector.com to take part!

Easter can fall anywhere between March 22nd and April 25th and is a time when many customs seem to symbolise renewal, life and the beginning of spring even here in the UK, despite the winter-like weather we have been experiencing! In Germany and Austria, many trees are decorated at this time with painted eggs, in celebration of the event (see front cover). At Weidmuller, this is the time we bring out our newest innovations at exhibitions such as the Hanover Fair and Railtex in April, and ES Live in May, as well as this, the first edition of the year of Connect UK to keep you up to date on the latest news with our product portfolios. In this issue, there is definitely a theme of cutting-edge technologies and making sure that we are ahead of the game when it comes to compliance with new standards and regulations, keeping down your costs in terms of maintenance, renewal and resources. We examine a forwardlooking technology for industrial controllers (Page 3), a new connectivity technology for reduced installation time in robots (Page 7), exceeding standards with our 2-pole testers (Page 8), UL certification for our crimped, insulated wire-end ferrules (Page 9) and we also look at the factory of

the future and what is being termed as the fourth industrial revolution or "Industry 4.0" (Page 11). This and other applications and discussion topics will soon be available on our new blog, and we invite you to follow us at www.weidmulleruk.wordpress.com/ and let us know your thoughts. You will also see at the top of this page that there is still just time for you to enter our VPU competition so why not have a go now? Hopefully you will also have taken advantage of our recent tools and printers promotions. Keep an eye out, there will be more on the way! Finally: PLEASE HELP US TO HELP YOU. We want to make sure that Connect UK is relevant for you and to that end; please may we ask you to take a little time to fill in the enclosed response card with your thoughts on what you would like to see in future editions of this Newsletter and kindly pop it back in the post to us. Many thanks.

3 3 4 - 7 4 4 5 6 6 7

DEVICE CONNECTIVITY INDUSTRIAL CONTROLLER ELECTRONICS INDUSTRIAL ETHERNET ROUTER PoE SWITCHES INDUSTRIAL ETHERNET COMMUNICATIONS SERIAL/FIBRE OPTIC CONVERTER PoE SURGE PROTECTION FREECON PASSIVE SC/RJ COUPLING

8 - 9 8 8 9 10 10 11 11

TOOLS GERMAN DESIGN AWARD 2-POLE TESTERS UL CERTIFIED CRIMPING MARKING SYSTEMS MULTICARD EXTENSIONS HANNOVER 2013 RAILTEX & ES LIVE 2013

11 EXHIBITIONS

DEVICE CONNECTIVITY
Forward-looking technology for industrial controllers Weidmllers practical connection solutions aid manufacturers of industrial controllers in all performance standards of automation and systems engineering. Excellence in compact solutions really is the name of the game.

Semiconductor engineering for industrial automation has made great strides in recent years. It enables us to produce controllers that are increasingly sophisticated. In addition, cost pressure and requirements relating to facility safety and compliance with industry-wide standards are increasing at the same time, explains product manager Gerd Richter. We have been following this trend closely and our product range has often been one step ahead of it. For example, you will see below how we optimised our male connectors for the automatic assembly process and reflow soldering procedure very early on. We are also responding to the trend for ever increasing numbers of sensors for monitoring purposes with an all-purpose choice of compact connection solutions. Precise signal processing in tiny spaces High-precision signal processing is needed for safe system operation with increasingly complex automation in as compact a space as possible. Our answer is a product range tailored specifically to the needs of sensor signals. For example, our 30-pole BL I/O connection system is currently the most compact 3.50mm version plug-in solution for connectors with three wires. Even if the controller isnt switched on, the signal display shows the correct sensor wiring. The associated electrical distribution supplies eight sensors with the voltage required. Solid PUSH IN wire connectors also guarantee that the sensors run continuously and safely. 3.50, 3.81 and 5.00/5.08mm plug-in solutions offer virtually unlimited design options for connectivity solutions. Our wide range of male connectors means the assembly components can be produced cost effectively and are equipped for the automated SMT process. PCB terminals with PUSH IN connectors offer a cost-effective alternative to plug-in solutions. They can be processed in both the wave soldering and reflow process without any compromise in SMD or SMT assembly.

Safe connections for actuators The actuators in a system need more than accurate status information. They also need secure connections to reliably control relays, valves and motors. These connections should take up as little space as possible to avoid the need for larger connection cross-sections, cable lengths, switching voltage, and overall assemblies. Our B2CF plug connectors have a high connection density while also being very easy to use. Up to four levels of the 3.50mm version can be set up to create a connection cross-section of no more than 1.5mm. The actuator conductors can be quickly and safely connected using the PUSH IN spring force. The BLF 5.0x which also features a PUSH IN connection is also ideal for stringent connection cross-section requirements.

"The whole range is compact

Our product range allows manufacturers of industrial controllers to select the device connectors that are most suited to their application. Even with this level of flexibility, there is one thing they can always rely on: the whole range being compact, says Richter. 72 Hour Sample Service An impressive introduction to our products can be experienced in advance through our configurator, which allows customers to design their own individual connection solutions online. Our unique 72-hour sample service enables development engineers to test their chosen solution as a sample in their device design, no more than three days after they have put it together. Just like our comprehensive design-in advice, we guarantee this service worldwide.

ELECTRONICS
Ensuring different networks inter-operate with top-level security Industrial Ethernet Router
Our router is designed for Gigabit Ethernet security applications in remote control or monitoring networks. It provides increased protection of critical assets in a wide range of applications, such as water treatments and controls systems in oil and gas applications. Communication networks used for office applications and for automation are converging. This means that procedures are more transparent and facilitate substantial data exchange. By connecting network components, our router enables network nodes to exchange data. It also allows an industrial IP network to access the Internet via an external DSL modem (via PPPoE). It is responsible for routing IP packets between an industrial network and external networks. Internet access is automatically activated when needed. The router can be configured on-site using an IP network on both Ethernet ports (LAN or WAN). It has extensive security standards to enable different networks to smoothly work together.

Production network

Machine network 1

Machine network 2

Encrypted transmission of your data via Virtual Private Networks VPN connections can be used to connect the router as a VPN-Client or a VPN-Server with other VPN devices. Our Industrial Ethernet router enables access to components from around the world, through encrypted VPNs using OpenVPN, as well as IPSec technologies, thus ensuring top-level security with minimum effort Safe integration of machines into a production network with Gigabit-Ethernet Our router can translate the addresses between different networks using protocols such as port forwarding, 1:1 NAT (Network Address Translation) or masquerading. These functions hide all the Ethernet devices of a machine, such as control systems or remote I/Os, behind the router, so that they are protected. This is how the router communicates across Gigabit-Ethernet LAN/WAN interfaces. Intelligent firewall Our routers firewall has configurable filter functions which adapt to the network traffic they see (stateful package inspection). The firewall controls the traffic between different trusted networks and any unidentified data packets are prevented from accessing your industrial networks.

Production network

Machine network

Simplifying the installation of Ethernet enabled devices Power over Ethernet (PoE) switches
The main advantage of Power over Ethernet is that you do not require a separate power supply cable and so can install Ethernet devices in hard-to-reach places or in areas where there is not sufficient room for many cables. This means that you can save on significant installation costs, and you can also integrate the power supply into a central uninterruptible power supply (UPS) to improve the reliability of the connected devices. PoE is used by network devices that need small amounts of power. It is typically used for IP telephones, network cameras, operating panels or wireless communications devices such as WLAN access points. Power over Ethernet (PoE) describes a process where power can be supplied to a network-compatible device over the 8-wire Ethernet cable. In effect, PoE today means the IEEE 802.3af (DTE Power over MDI) standard which was adopted in June 2003. Weidmller PoE switches support the IEE 802.3at standard (also known as PoE+) and can therefore supply end devices with up to 30W per PoE port. Our PoE switches also offer further advantages by their simple power supply needs. Currently, PoE requires a 48 V DC input, making it difficult for integration into industrial automation applications where 24 V DC is the typical control voltage. Users must install an additional 48 V DC supply for their PoE devices. This in turn means higher costs, increased installation and maintenance and a need for additional space. Weidmller offers PoE switches which do not require an additional 48 V supply in addition to the standard 24 V supply. The power input has a wide range of 20-60 V DC which makes the products suitable for industrial markets such as factory automation. Critically, our PoE switches offer dual power inputs, which provide excellent redundancy capabilities and improve system reliability. When one of the power inputs fails, the device is able to continue working by obtaining power from the other input.

ELECTRONICS

Your Industrial Ethernet Communications are always at work We enable them to keep you up to date
You should receive a seamless flow of information to optimise the productivity of your production cells from networking the communication between machine segments, to the exchange of information with high-level office networks. In this way, you can constantly monitor the activities of your robots. To provide you with seamless communication without media discontinuities, we offer you a comprehensive Industrial Ethernet product portfolio from field to control level. Thanks to the innovative STEADYTEC technology, our plug-in connectors create a resistant foundation for reliable and standardised connection solutions in data communication, both in the office and in harsher production environments. With functions such as high-speed ring redundancy or redundant power supply, our active Industrial Ethernet components guarantee uninterrupted operation of your production network. Extensive network management functions effectively manage your data traffic. Our Powerover-Ethernet switches will supply the operating voltage to the cameras that monitor your manufacturing processes, in parallel to data traffic. With these and many other functions, our multi-faceted Industrial Ethernet portfolio supports your communication from the control level down, through the infrastructure level to the machine level, meaning that channels of communication with your robots are always open.

Active Industrial Ethernet components Unmanaged switches (Fast Ethernet, Gigabit Ethernet) Managed switches (Fast Ethernet, Gigabit Ethernet) Power-over-Ethernet switches (unmanaged, managed) Media converters (copper, fibre-optic cables) Serial / Ethernet converters Industrial wireless components Industrial security routers

Plug-in connectors and cabling systems IEC-normed plug-in connectors, in 1, 4, 5, 6, and 14 variants All in Cat. 6A and with STEADYTEC technology Cables pre-assembled and sold by the metre Copper and fibre-optic cables IP 20 and IP 67 All required industrial connections: RJ45, M12, SC, ... Comprehensive range of accessories

ELECTRONICS

Transmitting serial data securely over long distances in large facilities Serial/Fibre-optic Converters
Status signals are sent to serial interfaces in many applications. If immunity from high interference is required or there are far-reaching systems, the 15 metre limit on cable length, e.g. using copper-based interfaces for RS-232 transmission, quickly becomes a restricting factor. Our solution for this application is our media converters, which convert serial signals from an RS232/422/485 port into fibre-optic signals with an SC or ST glass fibre connection. Fibre-optics, with multimode technology, make it possible to transmit over distances of up to 5km without additional power boosters. Reduced installation costs Our media converter connects serial devices in a fibre-optic circuit. This enables configuration of networks of up to 100km in length. Ring operation The media converter is able to connect several serial devices to form a glass fibre ring. This simply involves connecting the Tx port of one converter with the Rx port of a neighbouring converter. Ring mode can then be activated using the DIP switch on the device. A signal which is transmitted by a node is then forwarded in the ring until it is gets back to the sender, where it is blocked. In this way, glass fibre rings can be configured with a spread of up to 100km.

RS-485

IE-MCT
RX TX TX RX RX TX RX TX

IE-MCT
RS-485

IE-MCT
RS-485

IE-MCT
RS-485

Fibre-optic distances up to 5 km
RX TX RX TX

Transmission of serial data over longer distances Serial signals can be routed from an RS-232/422/485 port to fibre-optics with SC or ST connectors to span greater distances without additional power boosters. Automatic baud rate detection Our serial/fibre-optic converter can automatically detect the serial baud rate of connected devices. This ensures that signals can be forwarded by the media converter without any data loss, even if the baud rate of a connected device changes.

IE-MCT
RS-232

IE-MCT
RS-232

Protecting PoE Devices from lightning and induced power surges Data surge protection
You can increase the reliability and security of your network devices by installing our new V Data surge protection. Designed to protect PoE devices from the effects of lighting and surges, the V Data devices are suitable for Cat.5 (up to 100 MHz) and Cat.6 (upto 250 MHz Class E) and are also suitable for PoE (acc. IEEE 802.3af) and PoE+ (acc. IEEE 802.3at) offering protection of all line pairs (8 Wires).

ELECTRONICS

FreeCon Passive SC-RJ coupling New connectivity technology for reduced installation time in robots and IP 65/67 field cabling
We have small, easy to install, extremely durable connection components for equipping robots. They are quick to attach and detach, so as not to lose unnecessary time while servicing. With these needs in mind, we have added a new product to our FreeCon series: the SC-RJ coupling for fibre-optics 1. Rapid replacement Using the push-pull, plug-in connectors in our FreeCon product series, replacing hose packets is a quick, easy task. (multimode and POF) is extremely compact and flexible, due to various installation options, and protection from dust and spray water at IP 65. These and other advantages make our FreeCon product series the ideal solution for applications such as robot cabling in the automotive industry. 4. Fit for harsh environments The durable metal housing facilitates safe use in especially harsh industrial areas, such as welding robots.

2. Durable interfaces The coupling features stable engineering and IP 65 protection.

5. Flexible mounting There are diverse mounting options: in the front on a mounting plate or with a mounting foot that swivels 120.

3. Standard plug-in connector housing The plug-in connector housing is compliant with IEC 61076-3-117 and the standards of AIDA (Automation Initiative of German Automobile Manufacturers).

6. Variety We have a broad range of options in the FreeCon portfolio for you to choose from.

You can find more information by clicking here or at www.weidmuller.co.uk/uk/freeconpassive

TOOLS

Winner of 2013 German Design Award German Design Council acknowledges Digi Check Pro, 2-pole voltage tester for its intelligent product design and excellent functionality
Weidmller received the coveted German Design Award for its Digi Check Pro voltage tester in the category of Industrial Goods. The prize was awarded by the "German Design Council", a foundation that pools together the strengths of design experts around the world to promote good design. The independent jury of experts selected 90 outstanding products from more than 1,500 products nominated entries. Design plays a crucial role with industrial goods which is why these products have their own category in the competition. Our voltage tester impressed the jury with its combination of functionality and design, including, for example, its dust and water-proof casing. The device is used in industry to measure voltages in switch cabinets and is a standard piece of equipment for electricians. "The Digi Check Pro, 2-pole voltage tester combines intelligent product design with standard testing functions. The device can be used for all purposes thanks to its wide measurement range of 5 to 690 V", praised the jury. Another feature is the innovative latch system of the test probes, which enables quick and reliable testing with just one hand. "A professional mechatronics tool that looks good with a great ergonomic design. Simple. Straightforward. Good., evaluated the jury. "We develop tools that are both functional and ergonomic, based on our customers' requirements. We combine this user orientation together with innovative design. We are very proud that this has also been acknowledged by design experts with practical experience" enthused Dr. Christian Zimmermann, Head of the Tools Business Unit.

Exceeding the standard voltage testing with 2-pole testers Six new variants "Made in Europe"
Our 2-pole voltage tester is a standard, basic tool for every electrician. All six Weidmller variants already conform to the revised standard for 2-pole voltage testers (DIN VDE 0682401:2011, DIN EN-61243-3:2010) and all testers are TV/ GS-certified. The testers are available on the market in the high protection class IP65. They are classified in accordance with overvoltage category CAT IV 600 V. The new voltage testers are also resistant to temperatures from -15C to +45C. The necessary tests to ensure electromagnetic compatibility have been updated in line with standards in order to protect human life and the environment. Both the top variants, Digi-Check Pro and Combi-Check Pro, set benchmarks with their wide variety of functions. The four additional variants, Digi-Check, Multi-Check, CombiCheck and Master-Check, focus on functional highlights and offer optimum value for money. The digital voltage testers are also equipped with a large LCD display that has a bar chart. They offer test probe protection as well as a "Hold" function, and a battery-conserving light sensor that activates the backlit display. All 2-pole voltage testers automatically detect the voltage type (AC/DC) and they also display the polarity. In addition to the phase testing relative to earth, continuity and semiconductor tests (even one-handed) are also part of the obligatory range of tests. The high level of input resistance provides protection against contact.

TOOLS

Wire-end ferrule including crimping now UL certified. Weidmller's crimped, insulated wire-end ferrules have now been granted UL certification in addition to existing CSA-US, DIN/VDE and VG certification. The connection as a whole has been certified not the individual components.
Underwriters Laboratories certified the system, meaning the wire-end ferrules together with the hand tools and automatic strippers and crimpers used for the crimping process. The hand held tools are the types PZ4, PZ 6/5, PZ3, PZ6 roto, PZ16 for wire-end ferrules with plastic collars, as well as the automatic Crimpex series strippers and crimpers, and the automatic CA 100 stripper and crimper. UL certification not only opens up opportunities in North America and Canada to export-oriented companies, but the now certified, solderless connections with crimped wireend ferrules also offer significant competitive and quality advantages for the European and Asian markets. The products certified are wire-end ferrules with plastic collars in single packages for cross-sections ranging from 0.25mm2 to 50mm2 (AWG 26-1) with the exception of 35mm2 (AWG 2) together with the corresponding hand tools and automatic strippers and crimpers. The classic wire-end ferrule is a tinned copper sleeve, which is placed onto the end of the wire where it is crimped. They are used to insert the conductor into the connection or terminal compartment without it splitting. Tinning finely stranded wire ends does not afford protection against splitting, because the tin solder or the tinned wire conductor begins to yield under the pressure of the clamping screw. This is not the case when crimping, which gives a reliable, permanent electrical and mechanical connection between the wire conductor and the crimp contact. To ensure this happens, it is imperative that the wire conductor (crosssection) and crimping tool are precisely designed for one another. This means that the wire ends will be fitted correctly with wire-end ferrules, and will not break off, even when subjected to heavy vibration loads. In comparison with non-insulated ferrules, wire-end ferrules with plastic collars offer an enhanced level of electrical safety as well as mechanical stability. Moreover, standardised colour-coded plastic ensures wire conductor cross-sections are easily identified. Users are able to choose between the DIN colour code and Weidmller's colour code. Wire-end conductors with plastic collars provide a flawless, gas-tight connection between the wire conductor and the ferrule. The twin wire-end ferrule is a sleeve with plastic collar into which two cables are fed simultaneously. Crimped connections have proven themselves repeatedly, over time. Although the plastic was already UL approved, approval still had to be given to the wire-end ferrule as a whole. Now approval has been given for the whole system, comprising wire-end ferrules, hand tools. strippers and crimpers, there is no obstacle left to worldwide acceptance. At Weidmller, we are fully prepared to meet all demands, with a comprehensive assortment. Our portfolio includes wire-end ferrules (to DIN 46228, Paragraphs 1 and 4), with and without plastic collars, for nominal cross-sections ranging from 0.14mm2 to 50mm2, crimp sets and special tools, strippers and crimpers and wire-end ferrule boxes, as well as boxes with coloured empty box inserts.

MARKING SYSTEMS
Application variety with MultiCard extensions Labelling systems for; terminal blocks, wires, cables and equipment
We have expanded the capabilities of our labelling systems with solutions that reduce costs, optimise processes and comply with safety regulations. All of our markers, printers and software are from one source and designed to work perfectly together. 1. SlimFix Redesign SFR Cable Markers Re-designed SlimFix SFR cable markers enable the marker to be fitted without the use of an insertion tool and reduce installation time by up to 30%. They are for use with cable diameters 1.7mm up to 3.7mm. (0.5mm 2.5mm). SlimFix are wire and cable markers featuring a space-saving design, which can be attached to wires after they have been terminated. They are made from halogen-free material and fulfil V2 flammability class requirements. Polyamide 66, Halogen-free material V2 flammability class Markers available in the proven MultiCard format 5. PM 2.7 / 2.6 Markers The PM 2.7/2.6 markers, arranged in a 3.5mm pitch, enable the labelling of the B2CF Omnimate signal connectors to be arranged in strips. Up to two characters are printed or different terminal points are identified by means of colour printing. 6. SM DIA 60-22 K Diameter Tag The SwitchMark polyamide self-adhesive 60mm diameter tag, for marking emergency buttons which require a 22mm diameter hole to be fitted. Adhesive film on the reverse ensures that it remains securely in place. The external diameter of 60mm offers plenty of space on the label for printing using the labelling software M-Print PRO enables the use of texts in rounded font.

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2. SlimFix SFX 9/24 S Cable Markers These incorporate a new feed-through construction for cable ties, reducing installation time by up to 50%. They are for marking cables, from 7mm in diameter plus, with cable ties to a max width of 4.8mm. 3. SwitchMark SM 42/42-30 K, SM 44/44-21, SM 46/46-30 Rotary Switches These 3 new variants facilitate the labelling of rotary switches by Kraus&Naimer (Type S0), ABB (Type ON and OL40) and Schneider-Electric/Telemecanique (Type K1 K2). A further variant for Eaton-Moeller (T0) is also available. 4. SwitchMark SM 35/18 K, SM 37,5/17 Legends The SwitchMark polyamide legends for plate holders fit 30mm control and signalling devices.

7. DEK 5/5 S Dekafix Markers DEK 5/5 S Dekafix marker is the same as the popular DEK 5/5 but with an angled printing surface, which improves the visibility of the marker when used with terminals like the ZDU 2.5 or PDU 2.5 8. TM-I 12/18 Cable Markers The TM-I 12/18 30mm long polyamide cable markers are for use with transparent sleeves. A pre-determined breakpoint (18/12mm) allows additional information to be added. The TM-I is easy to install and delivers secure marking. TM-I tags are compatible with many sleeves available on the market today. Their MultiCard format means quick and convenient printing with the PrintJet, MCP Plus Plotter, MCMobilo or STI-S pen systems. Thanks to the project name panels on the MultiCards, the tags are easy to separate and mount.

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EXHIBITIONS

Thinking about the factory of the future 8-12 April, Hanover Messe, Hall 11, Stand B60
Were itching to come up with new ideas, and indeed, we're always looking for new ways and how to create innovative solutions for the needs of our core industries. We want to anticipate, lead the way, enthuse and shape the present day as much as looking to the future. We are entering the fourth phase of the industrial revolution, that is, where real and virtual worlds come together and intelligently networked and self-controlled production systems emerge. Weidmller has already taken up the challenge of this trend, with connectivity solutions that are "communications-enabled" and which are able to act autonomously. This means we are in a unique position to partner with you and provide you with a smooth transition into the realms of the fourth industrial revolution or "Industry 4.0". We invite you come along and experience the ways in which we are delivering optimum added- value solutions now, and with the future in mind, for yourself, live at the Hannover Messe.

Industrial connectivity solutions to help increase railway revenues Railtex, 30th April 2nd May at Earls Court, London - Stand B77

Connect with us, at ES Live, on Stand ES49, Stadium MK, Milton Keynes Displays of our applications-based product line at ES Live on Thursday, 16th May.

Running a modern and high-performance transport system and maximising revenues is a great logistical challenge and demands a fast, flexible, efficient, reliable and safe railway service for your customers, and one which requires short periods of immobilisation and servicing. Our staff will be on hand on stand B77 at Railtex 2013 to show and discuss solutions on offer for the electrical connection, transmission and conditioning of power, signals and data for rail infrastructure and trackside applications, signalling and rolling stock. Our connectors, terminals, enclosures, Industrial Ethernet, PCB components, surge protection, relays and tools will all be on display.

Our range includes PCB terminals and connectors; panel feed-through terminal blocks and electronics housings for industrial applications, with emphases on signal, data and power electronics. This free, prestigious, one day event will give you a chance to see how our OMNIMATE connector and enclosure ranges provide you with the perfect solution for your application.

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www.weidmuller.co.uk
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Let's Connect.
Weidmuller Ltd. Back Issues: If you would like to order any back issues of Connect UK simply email us at marketing@weidmuller.co.uk Contributors to this issue Editor Designer Electronics Tools lesley.young@weidmuller.co.uk ashley.hutchinson@weidmuller.co.uk peter.croucher@weidmuller.co.uk adrian.hinks@weidmuller.co.uk Klippon House Centurion Court Office Park Meridian East Meridian Business Park Leicester, LE19 1TP Sales: Technical: 0845 094 2006 0845 094 2007

Device Connectivity ivor.hunt@weidmuller.co.uk

www.weidmuller.co.uk marketing@weidmuller.co.uk

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