Transfer module
More space in the switch cabinet
The new generation of compact Varioface interface modules is the link between the remote I/O systems and the field level. An innovative design ensures fast and error-free wiring and saves space in the control cabinet.
Typically, a control cabinet consists of a control level, followed by an I/O and interface level and finally a field level. To connect the individual levels, around 97% of the various devices are currently wired individually, which is costly, time-consuming and prone to errors. One example of this is the single-wire wiring of a 32-channel digital output module. In a conventional approach, up to 80 cable ends have to be cut to length, stripped and, in some cases, fitted with ferrules and crimped. The 80 prepared cables must then be connected one by one without errors according to the circuit diagram. The cable may be connected to the wrong terminal point. In the worst case scenario, the user only notices this when the machine or system is commissioned. This is followed by laborious, costly and time-consuming troubleshooting, which is complicated by full cable ducts.
System cabling is a significant improvement on conventional installation. A suitable solution includes a front adapter, the system cable, modules or adapters and accessories. The interaction of these tested components creates a concept that can be installed easily, safely and quickly. The front adapter, which routes the signals, connects to the I/O card of the control system. Depending on the manufacturer of the I/O card, the appropriate adapter is either plugged or screwed onto the card. The user then connects the front adapter to the first end of the pre-assembled FLK or D-Sub system cable. The cables are available in different versions in terms of length, number of poles and shielding. This is also done quickly and easily using plug-and-play. In total, the user saves up to 90 % time and 60 % space compared to conventional solutions.
Visual and haptic addition
The new remote I/O systems from the various manufacturers - for example Simatic ET 200SP from Siemens, Smart Elements from Phoenix Contact and solutions from Beckhoff or Schneider Electric - have a similar basic design and orientation. All modules have a narrow design and vertical alignment. Push-in terminals are used to connect the wiring to the field level. The design of the Varioface Front Connect transfer modules from Phoenix Contact follows this line and is therefore both visually and haptically a suitable addition in terms of system cabling for the various remote I/O systems.
The innovative design of Varioface Front Connect ensures fast and error-free wiring at field level. Conductors with a cross-section of up to 2.5 mm2 and wire end ferrules can be connected to the push-in terminals, which are based on front connection technology. Thanks to the colored push-in spring openers, it is immediately clear to which connections the signals or the supply are to be connected. The plug-and-play connection to the remote I/O level is made using coded IDC/FLK or D-Sub connectors, so that all card signals can be connected quickly and with reverse polarity protection in a single step. Thanks to its high flexibility and slim design of just 19 mm, Varioface Front Connect supports decentralized peripherals. The user also saves up to 60 % space in the control cabinet.
More clarity through basic macros
The special VFC-PT/FLK14/PLC transfer module makes it possible to connect sensors with a three-wire connection easily and conveniently. Thanks to the integrated potential terminals with colored pushers, there is no need for additional potential distribution terminals. The module, which is designed for eight channels, offers an IDC/FLK14 connector to the I/O system. 16- or 32-channel I/O cards can also be easily connected via plug-and-play using so-called splitting cables.
A project always starts with planning. To make the implementation of system cabling with Varioface Front Connect as easy as possible for planners and system integrators, there is a suitable 3D/2D model and the respective Eplan macro for all modules. The Eplan macros were developed with various customers and users. Until now, a macro for a transfer module was displayed on a circuit diagram page. This variant had the disadvantage of being very confusing. With the new macros, there is now a basic macro in each case, in which, for example, the power supply has been accommodated. Furthermore, the planner can position the individual channels individually in the circuit diagram and on the corresponding diagram page. In this way, no jump marks need to be set and clarity is improved. Another new feature is that the system cables are now visualized with a single pole and no longer each wire individually. The routing of the signals is displayed in a table. This saves time and money during project planning.
Varioface Front Connect fits into the Complete Line system. In addition to the Eplan macros described, Complete Line includes coordinated hardware and software products, consulting services and system solutions for optimizing processes in enclosure construction.
Implementing complex requirements in a team
Relays can be found in almost all applications and control cabinets. The PLC interface relay system from Phoenix Contact forms the interface between the controller and the system peripherals. The universal design of the product family proves to be compact and therefore space-saving. While the 6.2 mm narrow module has one contact, the 14 mm version is available with two contacts. Depending on requirements, the modules can be fitted with electromechanical or solid-state relays. The system cabling adapter enables fast, simple and error-free connection of relay modules to the control unit.
The PLC interface product family is a solution for all requirements. The relays can be easily connected to the system cabling via a plug-in V8 adapter in a group of eight using plug-and-play. This also eliminates the need for tedious, cost-intensive single-wire wiring to the I/O system. To ensure that potentials can be connected quickly and conveniently, the user inserts endless jumpers into a separate jumper shaft. This means that no additional potential terminals are required. Special sensor/actuator series are also available with which the sensors or actuators can be connected directly to the relay channel with the corresponding supply voltage. All electromechanical and solid-state relays have a plug-in design and can be easily replaced during maintenance without disconnecting the field wiring.
Helge Blome, Phoenix Contact Electronics
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