SensoControl supports you in monitoring your processes safely and preventing failures
Downtime is the biggest threat to manufacturing efficiency. Every minute a piece of job-critical equipment is down equals lost revenue, but the costs don’t stop there. The effects of downtime can be felt throughout the company.
With SensoControl, end users can monitor their equipment for any system changes in real time, and optimize their equipment before an issue results in downtime. Effective diagnostics can also help users become more efficient by helping them to identify and remove process bottlenecks.
SensoControl: Sensor and Control Systems for Industrial Process Automation
SensoControl encompasses a range of sensors, signal conditioners, and compact controllers, designed for demanding applications in the manufacturing and processing industries. The product family focuses on precise measurement variable monitoring, robust installation solutions, and directly integrable interfaces for PLC and control systems. Key factors are measurement accuracy, long-term stability, industrial protection ratings, and compatibility with common fieldbuses and analog signals.
Product Classes and Designs
SensoControl supplies pressure, temperature, level, and proximity sensors, as well as signal converters and compact PID controllers. Housing variants range from space-saving M12 connectors and metal tube housings to IP67-protected plastic housings and solid stainless steel housings in IP69K design for cleaning and wet areas. Sealing and connection concepts are based on process standards: sensory transducers with ceramic or silicone-free membranes, screw connections in G1/4 or G1/2, hygienic G1-A and Tri-Clamp connections for food and pharmaceutical environments.
Electrically, standardized variants with 4–20 mA and 0–10 V output are available, as well as digital interfaces (IO-Link, Modbus RTU/TCP, Profinet). Supply voltages often start at 8–30 V DC; special controllers support 24 V DC standard supply or 230 V AC depending on the installation situation. Connector variants include M8/M12, Binder, and PG screw connections; for high shock and vibration resistance, potted electronic modules and lockable mounting clips are available.
Measurement Principles, Accuracy, and Calibration
For pressure measurements, piezoresistive sensors with fully sealed electronics are used. Typical accuracies range from ±0.1% FS to ±0.5% FS; industrial standard variants are around ±0.25% FS. Temperature sensors use PT100/1000 resistance elements or NTC/Pt converters with measuring ranges up to 500 °C and repeatability in the range of ±0.1 K. Level measurements are covered by hydrostatic, capacitive, or ultrasonic principles. For abrasive or foaming media, non-contact ultrasonic or radar options are provided, while hydrostatic sensors are preferred for closed containers and storage tanks.
Calibration is performed ex works according to DAkkS or ISO standards upon request. Field calibrations can be carried out directly on-site via remote calibration interfaces and teach-in functions. For applications with high accuracy requirements, sensors with temperature compensation and automatic drift correction are available.
Materials, Seals, and Chemical Resistance
Housing materials are selected based on the chemical load and mechanical stress of the application site. Stainless steel 1.4404/316L is standard for corrosive and hygienic applications. For aggressive media, special alloys and coatings are used. Membranes and media-contacting parts can be selected from Hastelloy, PTFE, or ceramic materials. Sealing systems use EPDM, FKM (Viton), or PTFE depending on temperature and media requirements. For high temperatures or contact with solvents and acids, the use of PTFE seals and corrosion-resistant materials is recommended.
Connections, Mounting Options, and Protection Ratings
SensoControl products are designed for direct process connection or installation in distribution and measuring points. Screw and flange connections are available in hygienic design or with threads according to DIN/ISO. Mounting options include carrier plate mounting, pipe clamps, and control cabinet installation. Protection ratings range from IP65 for dry industrial environments to IP67 for splash water and IP69K for high-pressure/hot water cleaning. For potentially explosive areas, ATEX and IECEx certified variants are available.
Interfaces, Signals, and Integration
Analog and digital interfaces are a core component: 4–20 mA with HART protocol supports remote configuration and diagnostics; 0–10 V allows simple PLC coupling. Digital protocols such as IO-Link simplify parameterization and device data management, while Modbus RTU/TCP and Profinet enable direct integration into control systems. Field devices offer status and error diagnostics, overload protection, temperature thresholds, and operating hour logging. For easy retrofitting, signal converters and galvanic isolation amplifiers are available in the product range.
Application Examples — Structured Practical Cases
1. Hydraulic Test Bench, Pressure Monitoring: A piezoresistive pressure sensor with G1/4 connection and 4–20 mA output is installed in the return line. The stainless steel membrane and EPDM seal ensure resistance to hydraulic oil. The sensor is connected to the PLC on the test bench via 4–20 mA, the signal value is linearized in the control system and used in real-time for leak detection and test logging. If the test bench operates at elevated temperatures, integrated temperature compensation ensures stable values.
2. Food Processing, Level Measurement: A capacitive level sensor in hygienic Tri-Clamp design is mounted on the tank nozzle. The sensor surface is smoothly polished and the housing is made of 316L; PTFE seals prevent contamination. The sensor communicates via IO-Link with the MES and provides continuous level values as well as diagnostic data on cleaning frequency. Recalibration is performed online using teach-in after cleaning cycles.
3. Paint Shop, Temperature Control: A PT1000 sensor in a protective tube measures the flow temperature of a circulation. The signal is fed to a compact SensoControl PID controller, which controls a 0–10 V heating module. The control uses adaptive ramps to prevent overshoot, and the controller displays limit values and downtimes in the plant visualization. Installation in the control cabinet uses plug-in terminals and M12 connections for easy maintenance.
Further specific case studies and application examples can be found at maku-industrie.de/anwendungsbeispiele. Technical information on integration and system technology is available at maku-industrie.de/technik.
Selection Criteria and Specifications for Purchase
Choose a product based on measuring range, accuracy, material compatibility, connection type, and interface compatibility. Check the required protection rating for the application site and approvals (ATEX, IP69K, UL). Pay attention to mechanical load capacity, vibration tolerance, and mounting options to reduce service times. For retrofit applications, compact signal converters with galvanic isolation and configurable output signals are advantageous. Documentation and calibration certificates should be included in the scope of delivery to provide quality evidence according to ISO requirements.
- Important interfaces: 4–20 mA/HART, 0–10 V, IO-Link, Modbus, Profinet
Maintenance, Testing, and Lifecycle
Regular visual inspection of connections, seals, and fastenings prevents leaks. For pressure and temperature sensors, annual functional tests and, if necessary, recalibrations are recommended. In abrasive media, the replacement cycle of membrane components should be documented. Devices with diagnostic interfaces enable predictive maintenance by monitoring drift, operating hours, and temperature cycles.
Compatibility with Monitoring Systems and Industry 4.0
SensoControl devices support connection to SCADA and IIoT platforms. Digital protocols and IO-Link enable the reading of device parameters, statuses, and error codes. For predictive maintenance, test data and lifetime values are output, which are incorporated into cloud or on-premise solutions. Standardized data models allow for automated device filtering and spare parts planning.
Documentation and Certifications
Scope of delivery includes technical data sheets, wiring diagrams, test reports, and, if required, calibration certificates according to DIN/EN. For safety-critical applications, Ex certificates, RoHS and REACH conformity, and lifetime documentation are available. If necessary, we offer support for CE declarations of conformity and installation modalities.
FAQs
1. What protection rating do I need for cleaning with hot water high pressure?
For cleaning areas with hot water and high pressure, at least IP69K in stainless steel housings with appropriate membrane material and sealant selection (e.g., PTFE seals) and corrosion-resistant media-contacting parts is recommended.
2. How do I choose between 4–20 mA and IO-Link?
Choose 4–20 mA for simple, interference-resistant analog transmission over long distances and compatibility with older control systems. IO-Link is advantageous if you need parameterization, diagnostic data, and automated device management. Combinations are possible to combine robustness and data depth.
3. Are SensoControl sensors suitable for potentially explosive areas?
Yes, ATEX and IECEx certified variants are available. Pay attention to the specified Ex zone, temperature class, and correct installation in accordance with the operating instructions and local regulations.