IDEC Blog

Safe, Simple, Smart – and also secure: push-in terminals maintain reliable grip on industrial control panel wiring connectors

Feel secure knowing that push-in terminals enhance convenience and safety Push-in terminals can drastically reduce control panel wiring times. Once wired, they maintain a secure grip on the connections for long-term system safety. IDEC has implemented S3 (Safe, Simple, Smart) push-in connection technology across a wide variety of safety devices: PLCs, safety relay modules, switches, pilot lights, and more. Explore the range and your options with your regional sales team. What makes a push-in terminal so secure? When you push a wire into the wiring port, it pushes back a spring-loaded clamp inside the terminal. Once the wire is in place, the clamp starts to push back against the connector. This consistent pressure prevents the wire from moving. As the amount of pressure is constant, there is no risk of it eventually loosening. A push-in terminal maintains the same level of grip on an installed wire – and the direct, reliable electrical conductor connection – throughout its lifespan. Vibration resistance: reliable when installed near machines and moving parts As the wire is held firmly in position, the potential effects of vibration and shocks are significantly reduced. Industrial equipment can vibrate during operation – often caused by the motor or generator running the machine, or components moving inside. This vibration is normal, and typically minimal. In other cases, repetitive back-and-forth movement is essential to the machine’s function. Industrial sanding machines, sorting conveyor belts and precision machine tools can all be classed as vibration-assisted machinery (VAM). There are also times when stronger vibration is a sign that the equipment needs maintenance. Wear and tear, misalignment and balance issues affect the dynamics of machine components. These problems can increase the amount of vibration and noise produced by affected equipment. No matter how the vibration is caused, nearby control panel components and wiring terminals feel the effects. For example, screws holding wires, connectors and parts together can be turned and loosened by vibrations – especially if they haven’t been tightened properly. We’ve previously explained how quick and efficient push-in terminal wiring can be. This time, learn more about one of the biggest benefits that push-in terminals provide after wiring is complete: reassuringly secure grip. Pull resistance: wires can’t be removed by accident In our catalogs and manuals for IDEC products with push-in terminals, we explain that wiring is simple: Step 1: push the wire straight in, to the back of the wiring port, as far as it can go. Step 2: lightly pull on the wire to confirm that it’s properly installed. We suggest giving wires a light pull – but they can withstand much more force than that. The pull-out force for push-in terminals is higher than that for screw terminals and spring clamp terminals. A wire that’s been correctly installed in a push-in terminal won’t loosen or fall out. The chances of pulling a wire out by accident are reassuringly low. This level of reliability is essential in many industrial settings. International safety standards and best practice guides for industrial control panel wiring emphasize the importance of correctly installing wires and storing slack. Loose or disconnected wires can lead to significant equipment downtime and workplace safety hazards. The simple, safe way to remove wires from a push-in terminal – when ready – is: press and hold down the pusher with a flat blade screwdriver, and carefully pull out the wire.

Easily convert your existing trolley into electric power-assisted rolling equipment with ez-Wheel® Assist Wheel Drive

Industry applications where Assist Wheel Drive excels Manufacturing : retrofitting rolling equipment that moves materials between production lines and different stages of the manufacturing process can streamline workflows. Healthcare : the Assist Wheel Drive 160 is specifically designed for use in medical settings. Hospital trolleys and other trolleys used to transport patients and supplies are easy to upgrade – maintaining a high safety level for everyone involved. Pharmaceuticals : turn sterile containers, stainless steel lifting trolleys, pharma rolling material trolleys and more into motorized equipment for smoother transportation. Logistics (retail, etc.) : workers who focus on picking and packing won’t need to spend as much time and effort on the process. Power-assisted trolleys are also easier to push across longer distances (such as warehouse floors). Food and packaging production: in temperature-controlled environments, time is of the essence to prevent hygiene/health risks and waste. Electric wheels keep things moving – forwards or in reverse. Step 3: Install and test the system The installation process is straightforward. Everything needed to convert standard rolling material trolleys will be provided: the wheel, the controller, cables, buttons and the mounting bracket. Once Assist Wheel Drive is fitted to the equipment, you can start using it immediately. The intuitive controls are simple to learn. See how it works in our installation video (with English subtitles): Fitting Assist Wheel Drive to your rolling equipment: what to think about Top 5 features and benefits of the Assist Wheel Drive system Use a trolley fitted with Assist Wheel Drive, and you won’t go back to manual handling Assist Wheel Drive is helping manufacturing businesses power ahead with improvements to both their industrial material handling and worker well-being. By retrofitting existing factory trolleys with electric powered wheels, you can improve operational efficiency, protect employees from physical harm, and bring down labor and equipment costs. Are you ready to bring a fleet of electric power-assisted rolling equipment into your manufacturing facility? IDEC offers the Assist Wheel Drive system in several global regions. 2. High transferable load limit The two versions of the Assist Wheel Drive system have different load capacities – both are impressive and can meet the demands of various industry applications. The Assist Wheel Drive 150 is designed for industrial environments. Thanks to the cast iron housing, it can support a maximum transferable load of 1,000 kg. The Assist Wheel Drive 160 is built for use in controlled environments and logistics, with a load capacity of 750 kg. 3. Ergonomic and safety benefits Assist Wheel Drive facilitates compliance with the ISO 11228-2 standard for ergonomics (manual handling part 2 – pushing and pulling). The system has been carefully designed to help reduce musculoskeletal disorders in the workplace. Step 1: Inspect and assess your equipment first In advance of installing the Assist Wheel Drive system, evaluate your current manual trolley fleet. Identify which ones are regularly used to transport heavy loads, and which ones would function more effectively with electric power assistance. In fast-paced industrial environments, moving materials (especially heavy loads) efficiently from point A to point B is key to success. Manually-powered trolleys are still in widespread use, but aren’t always optimized for ergonomics – adding to workers’ fatigue and limiting their productivity. An innovative solution that’s gaining traction in various industries is Assist Wheel Drive. The all-in-one electric wheel system is designed to be fitted on existing trolleys, instantly transforming them into electric power-assisted rolling material trolleys. Supported by Assist Wheel Drive, factory teams can transport heavy loads more easily, enhance their overall working efficiency, and improve workplace safety. In this article, we explain how rolling equipment can be converted into power-assisted versions with Assist Wheel Drive. Read on to learn more about the technology behind the system, the benefits, practical use cases, and tips for installation. 4. Productivity, efficiency, and well-being Heavy loads can be moved more quickly, without rushing or compromising on workers’ safety. As less effort is needed to transport the load, it may require fewer workers to do so – they can then focus on carrying out other tasks. Making the work simpler and safer drastically reduces the chances of someone being injured in the process. Sick days lead to more than just lost productivity: employee motivation levels and their willingness to do the work are equally important. How does Assist Wheel Drive work? The Assist Wheel Drive system is composed of an electric wheel and an ergonomic wired controller. The motor and battery are integrated within the wheel. This space-saving design also protects the parts inside, with reinforced cast iron and a shockproof housing. In the same way as the wheel can be installed on the underside of the rolling equipment, the controller is designed to fit onto the handle. It has an on/off button, forward and reverse controls, and a stop button for braking. Step 2: Decide which version of Assist Wheel Drive meets your needs The Assist Wheel Drive 150 is made for industrial applications. It’s the ideal power-assisted wheel on a mobile workstation, factory trolley or other rolling equipment. The Assist Wheel Drive 160 has an IP66 rating – full protection against dust, and strong water resistance. It’s suited to use on food and catering trolleys, as well as gurneys, chairs and beds. Assist Wheel Drive: the fully integrated industrial autonomous wheel Assist Wheel Drive is a clever system that works with you. It acts as a highly effective, flexible parts and material transport solution at distribution centers and warehouses, and in other industrial settings. Assist Wheel Drive is designed to both handle substantial amounts of weight and reduce physical stress on the workers transporting those loads. Electric assistance keeps the movement smooth and steady, reducing the risk of accidents and injury. Once installed, Assist Wheel Drive can support a maximum transferrable load of one ton (depending on the model – keep reading for more details). 1. Compatibility with existing equipment The ability to fit Assist Wheel Drive to any rolling material trolley you already use is an advantage in many industries. No matter what the equipment is made of – wood, steel, etc. – the electric wheel and controller are simple to install. At most, only minor modifications to the frame of the rolling equipment are needed. There is no reason, or need, to replace parts that are otherwise in good working order. By implementing Assist Wheel Drive, you can avoid the downtime and costs normally associated with replacing equipment. Step 4: Make sure workers are comfortable using Assist Wheel Drive The system is made to be user-friendly and reliable – even so, workers who will use Assist Wheel Drive-powered trolleys will benefit from training. Giving employees the opportunity to try the system in a real-world setting and learn the controls in advance will prevent future issues. 5. Long-term savings (ROI) Depending on the number of trolleys that need to be converted, implementing Assist Wheel Drive may represent an up-front investment. However, the potential cost savings over time are just as much of a benefit as the increased safety and enhanced productivity. In some cases, return on investment could be achieved in less than 12 months.

The power of IoT-enabled PLCs for predictive maintenance

Factories and other work sites that use industrial machinery rely on equipment maintenance to keep things running smoothly. Each part and component will need servicing at some point – without any maintenance at all, every machine will eventually break down. However, nobody can perfectly predict the future. The frequency and amount of maintenance needed depends on many factors: the equipment type, how long it’s been in use for, overall condition, etc. That’s a lot of information for workers to remember and keep track of. What if your manufacturing system could collect that information, analyze and present it in a way that makes industrial machine maintenance easier? IoT-based predictive maintenance using a PLC could be the answer you’re looking for. Before technological advances, humans had to simply wait and see For a long time, the most common form of equipment maintenance has been corrective maintenance (also called reactive maintenance). In other words: fixing something after it breaks. Downtime, repair costs and lower productivity are unavoidable in these cases. This type of unplanned maintenance is the most costly and time-consuming overall. Investing in the technology needed to perform other types of maintenance – explained below – may be expensive at the outset, but often results in higher long-term ROI. Predictive maintenance: decision-making support based on real-time data The Internet of Things (IoT) is a network of devices that collect and share data. Connected smart devices (e.g. voice-controlled lighting, appliances that can be used remotely, security cameras with motion sensors) are the ‘things’ in the IoT. When used in industry applications, the IoT is also commonly known as the Industrial Internet of Things (IIoT). IoT-based predictive maintenance is more proactive than preventive maintenance. This approach is also driven by data, making greater use of real-time information compared to prescriptive maintenance. The IIoT is ideally placed to bring predictive maintenance to industrial applications. As predictive maintenance depends on the IoT to provide the most accurate data, the PLC must also be compatible with, and connected to, the network. All of this means that a PLC with IoT integration is essential to build the most effective predictive maintenance systems for industrial equipment. IoT-enabled predictive maintenance: IDEC PLCs make it a reality Unlock the potential of the data that’s already available in your manufacturing system. Explore the IDEC website for more on the FC6A Plus and our other IoT-enabled PLCs. IDEC FC6A Plus: a PLC designed to handle large volumes of IoT data IDEC offers several PLCs with integrated IoT functionality. The FC6A MicroSmart Plus PLC has one of the most comprehensive feature lists: Up to 2,060 I/O points (a maximum of 511 analog I/O points) for connecting devices (when using expansion modules) Unlimited number of I/Os can be configured using the IDEC SX8R bus coupler module MQTT Sparkplug B Dual Ethernet ports , can be configured for FTP server/client communication Data logging via the SD memory card slot Compatible with open network protocols such as EtherNet/IP, Modbus TCP, and BACnet/IP 800kb of program memory (100,000 steps) , over double the data memory capacity of a typical micro PLCWeb server function, reporting and alerts via email The key to unlocking the FC6A Plus’s potential for user-centric predictive maintenance is the built-in WindLDR (Automation Organizer) software. It enables PID controls, custom reports and alerts, with no HTML programming knowledge needed. The role of PLCs in collecting and analyzing data from IoT-connected devices A PLC is the central control hub of many modern manufacturing systems. A PLC in the IoT (or IIoT) becomes one of the most important ‘things’ in the network. Connected devices use sensors to gather data from various equipment: temperature, liquid levels, energy usage, vibration and noise, and other key factors. Once gathered, the available data gives a comprehensive overview of the current state of the equipment. The next step is for the PLC to effectively help the operator to analyze this data and determine when maintenance is needed. Historical data (including failure data) and real-time data are used to precisely estimate the remaining lifespan and future health of the equipment. Operational issues can be identified far enough in advance to mitigate them. This means predictive maintenance is only carried out when genuinely needed (rather than on a fixed schedule), reducing downtime and associated costs. Required maintenance can be flexibly scheduled to minimize the impact on operations and productivity. Preventive maintenance: planned manual servicing on a set schedule As a broad term, preventive maintenance covers several types of proactive work: Usage-based (related to frequency of equipment use) Calendar/time-based (carried out on a pre-set schedule) Manual predictive maintenance (estimated based on equipment condition) Prescriptive maintenance (standardized strategy based on historical data) The schedule and maintenance level are based on the expected condition of the equipment at the time the work is done, not the actual condition. Even so, proactive preventive maintenance is preferable to corrective maintenance. With data collection, automation and other forward-thinking technologies, manual predictive maintenance of industrial equipment can be taken a step further.

When implementing a smart manufacturing system, an IoT-enabled PLC is the brains behind your operations

What makes a manufacturing system ‘smart’? In the context of Industry 4.0, ‘smart manufacturing’ means using digitalization and modern technologies to make basic manufacturing processes even more efficient. Importantly, those technologies (sensors, data analytics, the IoT and IIoT, robotics, automation, AI, machine learning and more) are built into the system from the start. Other, more traditional manufacturing models have fixed systems that are harder to change and upgrade in response to technological advances. Digital integration is limited as a result, and replacing individual parts of the system is only a temporary solution. How and where a PLC fits into a smart manufacturing system PLCs act as the hubs of modern industrial automation systems. As physical devices, they are central to OT architecture. The latest PLCs can do far more than just control and monitor equipment. They integrate and communicate with other systems, gather data, and provide visualizations and analytics to help operators make key decisions. Of these functions, it can be argued that connectivity and data collection are the most important – to smart manufacturing, to the IoT, and to Industry 4.0 overall. Many devices can now supply large amounts of operating data. The PLC that receives this information has to be able to handle, interpret and display it effectively. A PLC is the brain of a smart manufacturing system, and the Industrial Internet of Things (IIoT) becomes the backbone. The data collected from connected devices is shared throughout the system. The PLC can be programmed to analyze and present this information in the most suitable way for the specific application. Instead of OT vs. IT thinking, the IoT (and IIoT) can bring them together Traditional production models rely on operational technology (OT) architecture – human control and monitoring of devices and processes, and of the systems needed to run them. Robots, safety systems, PLCs, lighting controls, programming software, and scientific/technical equipment are all examples of OT. They can all be supported by information technology (IT) – data and cloud application management. Companies may see their IT system as separate to their manufacturing system, only relevant to emails, accounting, and other back-end information processes. However, technological advances mean that IT’s focus on data and OT’s focus on equipment are far more effective when combined. The fusion of OT and IT can create even greater possibilities than ever before, thanks to the Internet of Things (IoT). A network of connected devices sharing data is maybe the best example of how well they work together. The role that the IoT plays in smart manufacturing is to facilitate full system integration. Device compatibility is no longer an issue. Access to real-time information enables more responsive – and even proactive – decision making. Consider building your smart manufacturing system around an IDEC PLC Even as smart factories evolve, they continue to revolve around PLCs with IoT integration and strong adaptability. Read more about the FC6A Plus and our other IoT-enabled PLCs here on the IDEC website. Every business wants to work ‘smarter’ to stay competitive in their field. That could mean streamlining their processes, using project management systems, or making the most of automation tools. In industrial settings, a smart manufacturing system can reduce labor costs, improve product quality control, lower the risk of accidents, and prevent wasted energy and resources. These wide-ranging advantages mean that the adoption and use of smart manufacturing is growing rapidly on a global scale. The automotive, food and packaging, semiconductor and construction industries are leading the way, transforming their facilities into ‘smart factories’. The shift towards the smart factory model is led by a familiar piece of equipment: programmable logic controllers (PLCs). They continue to play a vital part in industrial automation, and can support smart manufacturing systems with forward-thinking features. IDEC FC6A Plus: an IoT-enabled PLC with numerous smart features IDEC PLCs can provide the integrated IoT functionality needed to implement a smart manufacturing system. As one example, the FC6A MicroSmart Plus PLC has a variety of clever built-in features: Scalability of digital/analog I/O points : up to 2,060 I/O points (up to 511 analog I/O points) (when using expansion modules) IIoT ready : dual Ethernet ports, compatible with open network protocols such as EtherNet/IP, Modbus TCP, and BACnet/IP MQTT Sparkplug B Reliable data handling : more than double the memory capacity of a standard micro PLC E-mail notification : e-mail instruction can be used for alerts when a connected device causes an error The FC6A Plus makes it simple to combine OT (connected devices) and IT (data transfer and management). Over 800kb (100,000 steps) of program memory and fast basic instruction processing and execution speeds ensure reliable responses to user needs and system changes.

Illuminated emergency stop switches on teaching pendants: the future of industrial safety looks even brighter

What makes this illuminated emergency stop switch, which complies with ISO 13850, a logical safety step? According to the requirements, the emergency stop function “shall be available and operational at all times” to meet safety standards. In addition, ISO 13850 includes a measure to indicate the active/inactive status of the switch by changing the color of the lighting. However, conventional e-stops with illumination are only partially lit up. The light may be harder to see as a result. If you want to use the color of the lighting to distinguish between active/inactive status, if the unit handle color is originally red then it is harder to determine whether the emergency stop is active or inactive. This means it is not easy to see if the unit is lit when indicating an active status. The switch handle on IDEC’s new XA/XW series illuminated e-stop is fully lit up whenever the function is active. If the button is not lit up in red, you immediately know it is not available or operational. The status can be confirmed from further away, from more angles, and in work environments with lower or minimum lighting. When mounted on a teaching pendant, an e-stop that lights up can support operators who are concentrating on other work processes. In other words, a teaching pendant equipped with IDEC's illuminated e-stop can clearly indicate a machine failure to you before an unexpected situation occurs. Teaching pendants and e-stops: long established as a reliable combination The e-stop has been an essential safety feature for industrial robot teaching pendants (also known as teach pendants) for many years. Even if the switch is rarely used, it’s important – and reassuring – for the operator to have one easily accessible at all times. This reliability has stayed true as teaching pendants have evolved: from wired devices to lightweight tablets with touchscreens and wireless communication. The importance of emergency stop switches hasn’t changed – that said, they have similarly moved with the times. As automated equipment continues to become smaller, the need for e-stop functionality is being met by a trend towards ever smaller solutions. The revised ISO 13850:2015 standards uphold the importance of the emergency stop switch, while incorporating market changes. Would you take a robot teaching pendant without an emergency stop button inside a safety fence where a robot is working? No, you wouldn’t. If the robot malfunctions or the operator is put in a dangerous situation, the emergency stop (e-stop) function can save their life and prevent damage and injury. Updates to safety standards also mean new ways to ensure compliance The specifications for e-stops to meet the requirements of ISO 13850:2015 are: “4.1.12: The emergency stop function shall be available and operational at all times . 4.3.6: The actuator of the emergency stop device shall be coloured RED . As far as a background exists behind the actuator and as far as it is practicable, the background shall be coloured YELLOW.” For the emergency stop function on portable operator control systems: “4.3.8: When emergency stop devices are installed on detachable or cableless operator control stations (e.g. pluggable portable teaching pendants), at least one emergency stop device shall be permanently available (e.g. in a fixed position) on the machine. In addition, at least one of the following measures shall be applied to avoid confusion between active and inactive emergency stop devices: device colour changing through illumination of the active emergency stop device; automatic (self-actuating) covering of inactive emergency stop devices; where this is not practicable, manually-applied covering may be used, provided that the cover remains attached to the operator control stations; provision of proper storage for detached or cableless operator control stations.” Up to now, emergency stop buttons haven’t used color illumination to indicate the active/inactive status. When users need to make it clear that the emergency stop function is inactive, they’ve often had to cover the switch or keep it stored in an appropriate location. IDEC’s XA/XW series of short body emergency stop switches offer a new type of illumination that complies with the requirements of ISO 13850:2015. They make it easy to determine the emergency stop function’s status based on the illumination: not lit up (off) when inactive, and lit up (on) when active. They also meet the requirements for an emergency stop, as they turn red when lit up (on). IDEC continues to lead the way with bright ideas and safety innovations Illuminated models are options in the IDEC XA and XW emergency stop switch lineups (white body with a red light, or red body with a red light). The newest XA series illuminated switches are fitted on the IDEC HT3P and HT4P Safety Commander tablet holders with built-in safety functions. On Safety Commander tablet holders, the switch is positioned for easy access with either hand. It visually and physically stands out from the other optional buttons and switches available. IDEC’s illuminated e-stop switches maintain the space-saving design, reverse energy structure, lock/opening mechanisms, and environmental protection ratings that users expect. The combination of a teaching pendant with an illuminated emergency stop switch is still relatively rare. You can explore this possibility with IDEC products and solutions right now.

New product release: IDEC 4.3” HG1J IIoT-ready PCAP HMI for an intuitive touch interface

A comparison of the HG1J and HG2J HG1J : Compact 4.3-inch display TFT color LCD (16.77 million colors) 32 levels of brightness adjustment Operating temperature range: -20 to +55℃ Available in black and silver HG2J : Sleek 7.0-inch display TFT color LCD (65,536 colors) 48 levels of brightness adjustment Operating temperature range: -20 to +60℃ Available in black Empower your connectivity with IIoT technology In manufacturing systems, HMIs and other devices need to not only display data but also enable seamless data sharing across networks. The HG1J and HG2J offer IoT functionality, multiple connection ports, and support for open network protocols. With two USB-A ports, these HMIs support flash drives for data logging, recipes, program transfers, and dongles for speakers or Wi-Fi. The embedded Ethernet port provides easy access for remote maintenance, while Modbus TCP/IP, BACnet IP, EtherNet/IP, and MQTT protocols enable connectivity with other intelligent devices. These connections allow the HMIs to function as gateways between the work site and the cloud. Once connected, the HG1J and HG2J can read data from other system devices and send it to cloud storage. Built-in RS232C and RS422/485 serial communication ports with Modbus RTU support let the HG1J and HG2J communicate with other serial PLCs or devices, such as barcode readers and temperature controllers. Seamless remote monitoring and control with Wi-Fi enabled HMI solutions System-wide communication is crucial to keep production lines and processes running smoothly. However, not every device in a manufacturing system is always on site or connected by control panel wiring. Wireless connections help bridge the gaps between facilities and remote equipment. By plugging a Wi-Fi dongle into the USB port, users gain wireless connectivity. In addition, the web server function enables device information to be remotely viewed on a PC or tablet. Operators can now monitor and control equipment without needing to be physically present. Data and controls are also accessible via a dedicated app. Many communication options are available for users to create automation and IIoT solutions. They can easily incorporate multiple industrial protocols, the FTP protocol, remote monitoring and control, email/text messaging, Twitter/X, iOS and Android apps, and custom web pages. Smart manufacturing calls for intelligent devices. Industrial equipment operators rely on HMIs that work with them – not just for them – to boost efficiency and productivity. A critical aspect of interface usability is display 'visibility'. Thoughtful placement and clarity are essential for effective control panel layouts. Devices must also be resilient in harsh conditions, adaptable across diverse work environments, and dependable for unmanned operations. To meet these varied demands, IDEC introduced the HG2J PCAP touchscreen operator interface. Now, the more compact HG1J HMI joins the lineup. A robust and durable HMI with an expansive, clear display The projected capacitive (PCAP) HMI combines a compact size with powerful functionality – ideal for space-limited applications. Its design maximizes display area while keeping a minimal footprint. The PCAP display is water- and scratch-resistant, highly responsive, and resists false signals from dirt or water droplets on the surface. The durable glass top design ensures long life, with a backlight rated for 50,000 hours, and requires minimal maintenance. It passed a 1kg steel ball drop test from 60cm (with protective film) without damage, demonstrating resilience against rough handling, harsh conditions, and water sprays. The HMI also supports multi-touch with thin glove compatibility. The tempered glass prevents UV clouding for lasting clarity, and the touch panel's lack of moving parts minimizes wear. The HG1J and HG2J are built to last, with a 3-year warranty. They also have ratings for extreme temperatures (-20 to 55˚C), IP66 and IP67 for washdowns, IP66F and IP67F for oil resistance, and UL61010, UL Type 4X/13, and Class I Div 2 for safety. Both HMIs are ideal for diverse applications and environments. Learn more about the HG1J and HG2J here on the IDEC website Contact your local IDEC team for specific advice on HMIs and tailored solutions.

Maximize the efficiency and reliability of your automation system with the IDEC SX8R bus coupler module

2. High level of safety The SX8R bus coupler module and FC6A I/O modules are products that comply with PLC standards (IEC/EN 61131-2), have the CE/UKCA mark, and hold UL/cUL, UL 121201: Class 1 Div 2, and RCM certification. As such, they can be safely used in major global regions. Depending on the location, industry, and operating environment, factory equipment can be exposed to extreme temperatures. The SX8R bus coupler module and the FC6A I/O modules maintain reliable performance in hot and cold environments, with a wide operating temperature range from -25°C to +65°C. 4. Network compatibility and device communication Enjoy support for EtherNet/IP (adapter), Modbus TCP (server), and CC-Link IE Basic (slave station), the leading networks for industrial use. Using these communication protocols, you can build a remote I/O system with a PLC or controller. As the SX8R is compatible with multiple protocols, you can connect a controller (PLC) and a monitoring device (HMI) to the SX8R at the same time. (Note: simultaneous connection of EtherNet/IP and CC-Link IE Basic is not possible.) 3. Simple, flexible installation Installing the SX8R is simple for 2 key reasons: its compact size and the use of push-in terminals. The SX8R can be mounted directly or on a DIN rail, so that it’s ideally positioned within your setup and takes up as little installation space as possible. Wiring time can be reduced by as much as 55% with push-in terminals, compared to wiring screw terminals. There’s no need to loosen and retighten screws with push-in terminals – or to use a screwdriver at all. 5. Easy setup and intuitive operation SX8R Configurator is the dedicated settings software with the SX8R, offered as a free download from IDEC websites. It helps users configure the SX8R’s transmission settings and each module’s operational settings, and enables module status monitoring. The SX8R Configurator program feels intuitive – even for first-time users. Start by using the ‘drag and drop’ function to create a layout of your SX8R and I/O module system. You can then configure each module’s operation via the user-friendly menu options. User-friendly features of the SX8R bus coupler module 1. Modular design and scalability You can choose from a wide range of I/O modules, with the ability to expand to up to 15 modules. This allows for exceptional customization to meet diverse application needs. The SX8R supports up to 7 I/O modules, and by adding the expansion interface module, an additional 8 modules can be integrated. With a total of 15 modules, the system can handle up to 480 digital I/Os, 120 analog inputs, and 60 analog outputs. This expansion capability provides flexibility in building a remote I/O system tailored to the scale of any automation setup. The SX8R is compatible with over 40 IDEC FC6A MicroSmart PLC I/O modules, supporting a wide range of discrete and analog signals. Factory automation is intended to help manufacturing processes run more smoothly by nature. Automating manufacturing processes can increase work efficiency and productivity, raise workplace safety levels, mitigate labor shortages, and contribute to sustainable manufacturing activities. To help realize factory automation, an important link in the chain of many remote I/O systems used at manufacturing sites is a bus coupler module. IDEC offers the SX8R bus coupler module: a device that’s compatible with a wide variety of control signals and helps to save space, wiring time, and labor costs. How the SX8R could simplify industrial automation and remote I/O systems Module configurations and I/O module setting parameters can be saved as project files for use in a future remote I/O system – a time-saving advantage during initial setup. Once the system is operational, you can use SX8R Configurator to carry out monitoring and diagnostics remotely. Information about each I/O module (on/off status for digital I/O modules, current values, set values and error information for analog I/O modules) can also be viewed remotely. If an error occurs, having data on the error type and a proposed solution can reduce the amount of system downtime. Where does a remote I/O system fit into your factory automation plans? The SX8R bus coupler module has the compact design and convenience needed in industrial settings. IDEC’s remote I/O system solutions offer control device compatibility, network connectivity, and flexible expansion. IDEC offers the SX8R bus coupler module and the FC6A I/O modules globally. Read through the product catalog and explore your options here on the IDEC website. What is the SX8R bus coupler module? We will explain the role of bus coupler modules in factory automation systems in terms of a remote I/O system. I/O modules form the system alongside the main controller, such as a PLC, and act as input/output interfaces for each control device (switches, lamps, sensors, etc.). I/O modules are either housed with the controller (local I/O), or in a different location to the controller and connected via network cables (remote I/O). Local I/O is also known as a centralized system, and remote I/O is also known as a decentralized system. Remote I/O systems are commonly used in a variety of industrial applications, including for automated production lines, food and packaging equipment, machine tools, and logistics. The control devices connected to the system may not all be in the same place – for example, on production lines or in logistics warehouses. Setting up a controller in each location would be inefficient and expensive. Connecting each control device to an I/O module using long cables would be complicated, take up space, and increase the risk of data transmission errors. To build a decentralized remote I/O system, the I/O modules by themselves aren’t enough. Local I/O modules connected to the controller can share data directly. Remote I/O modules send and receive data via a dedicated communication module with network protocol support. This is where the IDEC SX8R bus coupler module comes in. So that I/O modules can transmit data between connected control devices and the controller, the SX8R bus coupler module helps to compile, interpret, and send the control signals. The SX8R is made for factory automation systems that rely on stable communication between a central control system with a controller and the remote I/Os.

New product release: IDEC FT1J controller with operator interface

As Industry 4.0 continues to drive innovations in manufacturing, PLCs and HMIs in industrial settings must adapt to meet diverse user demands. Control is just one aspect. Interfaces must also save space, reduce energy consumption and costs, perform reliably in harsh environments, and provide the necessary connectivity for remote operation, monitoring, and maintenance. IDEC introduced the FT2J controller with an operator interface to help customers address these challenges. Now, the product line is expanding with the release of the FT1J PLC + HMI, offering an all-in-one automation solution in an even more compact design. Tempered glass for clarity, durability, and environmental protection Both the FT1J and FT2J models feature a projected capacitive (PCAP) reinforced glass touchscreen, offering a robust and modern alternative to traditional analog resistive touchscreens. PCAP glass panels remain relatively uncommon in operator interfaces, making this design choice a significant advantage for the FT1J and FT2J in terms of both physical and environmental durability. These units are designed to operate reliably across a wide temperature range of -20 to +55°C. In harsh environments, where the interface may be exposed to constant UV light, the reinforced glass prevents clouding, ensuring long-lasting clarity. Additionally, the glass top has an IP66F/IP67F rating, providing superior protection against water, oil, dirt, and dust – making both models ideal for use in challenging, messy, or wet environments. With no moving parts, the touch panel avoids mechanical wear over time, delivering consistent performance regardless of how hard it is pressed. In fact, the FT2J’s screen, equipped with a protective film, successfully passed a drop test involving a 1kg steel ball dropped from a height of 60 cm, demonstrating its toughness. This high level of external protection ensures the device's internal components continue to perform optimally, maximizing the overall reliability of the FT1J and FT2J in demanding applications. IoT connectivity, seamless integration and communication The FT1J’s compact design delivers powerful functionality with advanced IoT connectivity. At its core is a dual-CPU configuration, unlike similar products that rely on a single CPU for both HMI and control functions. By dedicating one CPU to HMI operations and the other to control tasks, the FT1J and FT2J achieve high-speed processing and rapid response times. The unit comes with up to 14 onboard I/O points, expandable to 22 I/O points to suit various application needs. Built-in analog inputs and outputs allow for seamless integration with complex control systems. Designed to handle advanced control functions, the FT1J includes PID control, Pulse Width Modulation (PWM), high-speed inputs, and script programming – offering the flexibility to address a wide range of automation challenges. For data logging, recipes, and program transfers, two USB-A ports support flash drives, and additional dongles enable features like speakers, Wi-Fi, and Bluetooth. The embedded Ethernet port allows easy access for remote maintenance and communication, while the unit supports multiple protocols – Modbus TCP/IP, BACnet IP, EtherNet/IP, and MQTT – for connectivity with other intelligent devices. Additionally, built-in RS232C and RS422/485 serial ports support Modbus RTU, enabling communication with serial PLCs or devices such as barcode readers and temperature controllers. All configuration for both the PLC and HMI is managed through IDEC’s intuitive WindOI-NV4 software, which offers a drag-and-drop interface and a comprehensive image library. Projects can be converted across different HMI sizes within seconds. Features such as script programming, PID loop control, PWM control, multilingual support, security settings, trend charts, data and alarm logs are fully integrated for both the PLC and HMI. With a unified program file that supports both, users can efficiently manage their automation projects. Sleek design that minimizes installation space and maximizes the display area Are industrial control panels shrinking? Some reports suggest this 'downsizing' trend is a noticeable outcome of Industry 4.0. More accurately, modern control panels are being engineered to save space. Optimized and intuitive layouts not only enhance operational efficiency, but also future-proof systems. The first step in creating a space-efficient control panel is streamlined device installation. The FT1J’s depth is nearly half that of a separate PLC and HMI, making it much easier to fit into tight spaces. Additionally, the detachable push-in terminal blocks simplify and accelerate wiring. Wherever the operator interface is placed on the panel, it must display information clearly without obstructing access to other controls. The FT2J, with its already compact 7.0-inch width, set the standard. The 4.3-inch FT1J display features 16 million colors and 32 levels of brightness adjustment, delivering vibrant visuals and customizable clarity for any environment. Both units provide ample display space to give operators a complete view of their data. The slim bezel maximizes the panel's surface area, allowing as much information as possible to be displayed on screen. Compare the IDEC FT1J and FT2J on the IDEC website To discover how the FT1J and FT2J controllers with operator interface could meet your specific needs, please get in touch with your local IDEC team. Which PLC + HMI to choose? A comparison of the FT1J and FT2J FT1J : Compact 4.3-inch display Approx. 1/2 the depth of a separate PLC and HMI (53.5mm) Up to 22 I/O points (analog and digital) TFT color LCD (16.77 million colors) 32 levels of brightness adjustment Weight: approx. 300g FT2J : Immersive 7.0-inch display Approx. 1/3 the depth of a separate PLC and HMI (35.3mm) Up to 30 I/O points (analog and digital) TFT color LCD (65,536 colors) 48 levels of brightness adjustment Weight: approx. 600g

Simplifying control panel wiring: how push-in terminals enhance efficiency in industrial applications

The more devices and switches that are installed on your control panel, the more wires you need to connect. The more wires you have, the more likely you are to need (and use) terminal blocks to keep them secure and organized. Terminal blocks act as ‘junctions’ for the wiring system, routing tens or hundreds of wires between input and output devices. They can be found behind control panels in many industrial applications (manufacturing, automotive, etc.) where complex electrical systems need to be installed quickly and safely. The rise of push-in terminals for quick, efficient and tool-free wiring When wiring a terminal block with push-in technology, you might feel like you’re missing something: a screwdriver. With screw terminals, you need to loosen the screw, insert the wire, and retighten the screw. With spring clamp terminals, you need a tool to hold the clamp open until the wire is inserted. The extra work time needed to secure each wire soon adds up. With push-in terminals and wires with a crimped ferrule (or solid wires), you don’t need to use a screwdriver at all. Keeping at least one hand free during the wiring process can improve concentration and reduce reaction time if there is an issue. The risk of injury is low, thanks to the IP20 finger-safe protection rating IDEC push-in terminals hold. How to install products with push-in terminals in your control panel Important safety note : make sure that electric power to all control panel devices is off before starting installation, wiring, inspection, maintenance and removal. Failure to do so may create a fire hazard or cause electrical shocks. All terminals need to be mounted securely on a suitable surface. That could be the back of a control panel switch, or on a DIN rail. For contact block mounting : IDEC contact blocks snap onto the back of compatible pushbuttons and indicator lights. Make sure that the locking ring is fastened before attaching the contact block. For DIN rail mounting : The DIN rail should always be horizontal. IDEC products designed to attached to DIN rails clamp or snap into place. IDEC products for control panels are designed to be compact, reducing the panel area and the amount of installation space needed behind it. They give you more room to create the optimum arrangement of terminals and wires. Three common types of terminal block Screw terminal : the traditional option. Spring clamp terminal : an evolution. Push-in terminal : the game-changer. Push-in terminals in their current form are a relatively new invention, but their popularity has rapidly grown. S3 (Safe, Simple, Smart) push-in connection technology enhances the appeal of many IDEC products, from automation devices to industrial components: FC6A PLC HG2J operator interface FT2J integrated PLC+HMI KW2D RFID reader HR2S safety relay module SJ/SU relay sockets HW switches and pilot lights CW flush switches and pilot lights The number and variety of IDEC products with push-in terminals reflects the widespread appeal, ease of use, and revolutionary nature of push-in wiring technology. Watch our timelapse wiring comparison video for control panel switches: A step-by-step guide to removing wires from a push-in terminal Step 1 : press and hold the pusher with a flat blade screwdriver. Step 2 : while holding down the pusher, pull out the wire. Again, it’s simple, and takes less time than loosening screws. On IDEC products with push-in terminals, the release tabs are yellow or orange to make them easier to find. They are essential for removal – pulling on a secured wire in a push-in terminal will add to the amount of force keeping it in place. A step-by-step guide to push-in terminal wiring Step 1 : push the wire to the back of the wiring port. Step 2 : give the wire a light pull to confirm it’s connected properly. That’s all you need to do. Using this quick and simple process, time spent on wiring work could be shortened by as much as 55% (compared to wiring a screw terminal). You can see the difference in this socket wiring video: For industrial users, push-in terminals offer practical solutions Push-in terminal wiring efficiency makes a real difference during control panel wiring. Add on the safety, convenience, and space-saving benefits that push-in terminals provide, and the choice is clear. You can continue to expect frequent product innovations and functional safety developments from IDEC.

Assist Wheel Drive: the electric wheel that helps workers safely transport heavy payloads

Improve workplace safety and employee well-being with Assist Wheel Drive Incorporating motorized equipment into manual handling processes can enhance health and safety for workers and reduce work-related injuries. The Assist Wheel Drive all-in-one system is compatible with the trolleys and carts that workers already use. The simple, integrated structure has universal compatibility and is simple to retrofit. Quick and easy access to trolleys powered by electric wheels could transform manual handling processes in your workplace. Set things in motion by learning more about Assist Wheel Drive now. The ez-Wheel EW1A Assist Wheel Drive series is designed to improve productivity and efficiency, and to reduce physical stress on workers when transporting heavy loads. A high load capacity makes Assist Wheel Drive electric wheels suitable for transporting heavy parts and equipment. The EW1A-150 wheels can effortlessly move a maximum transferable load of 1,000kg. To help you imagine it, here’s what 1,000kg looks like in various industries: Automotive: between 3 and 7 petrol engines Food and packaging: between 5,000 and 6,000 average-sized apples Logistics: approx. 8,000 square meters of bubble wrap Construction: between 43 and 59 standard concrete blocks Manufacturing: almost 17 meters of rubber conveyor belt (if 1m wide, and 20mm thick) Assist Wheel Drive is fully compliant with ISO 11228-2 (ergonomics – manual handling part 2 – pushing and pulling). The system makes a real difference in work environments where heavy loads need to be transported safely and reliably. Workers stay safer when using carts with electric powered wheels to transport heavy loads In many countries and industries, pushing and pulling are common causes of workplace injuries – especially back strain, sprains, and other MSDs. Pulling and pushing heavy payloads can result in other accidents, such as trips, slips and falls. Workers are at risk of injuring their fingers and hands – for example, if their hand is trapped between the trolley and a surface. Trolleys in motion can bump into a worker’s legs or run over their foot. A motorized trolley (with an electric wheel) that is easier to move and control can mitigate all of these risks. The Assist Wheel Drive controller has forward and reverse controls, and a stop button. The trolley’s speed, braking, and other settings can be easily adjusted using the dedicated ez-Config PC software. Improved ergonomics reduce musculoskeletal injuries in the workplace ISO 11228-2 is an international standard for ergonomics. It contains guidelines and requirements for preventing work-related musculoskeletal disorders (MSDs). Manual handling puts workers at repeated risk of MSDs. As the body’s musculoskeletal system includes the bones, joints and muscles, MSDs include: muscle sprains and strains back injuries bone and joint injuries nerve damage chronic pain conditions Assist Wheel Drive is engineered to prevent musculoskeletal disorders in the workplace, by reducing manual efforts and repetitive strain. The potential positive impact of the system goes beyond individual employees’ health. Lower risk of injury reduces the number of working days lost to sick leave. Overall, workplace productivity could rise by as much as 50%. Humans can focus on pushing the payload, not their physical limits When pushing, pulling, lifting or carrying items, the weight of the load is a key consideration. W orkplace health and safety standards in different countries vary. They agree on one thing – setting a fixed weight limit for manual handling is difficult. This is because the amount of weight that a person can safely lift, carry, push or pull depends on: their heights and weight their overall strength and frequency of their efforts their position, stance and posture the amount of friction on the floor how far away from the load they are how far the load needs to be transported, and how long it takes to move As a result, workplace load limits are often based on the amount of force needed to set a load in motion and keep it moving. ISO 11228-2 also defines acceptable force limits for manually handling loads. Electric power assistance via the wheels means less human force is needed to move a payload. Assist Wheel Drive helps workers by cutting the amount of physical effort required by as much as four fifths.