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YOU PAY FOR . . . from

Product Focus: Process Control and Instrumentation

0719-16pager-process_instrumentation-FONTS.indd 1 6/27/19 2:23 PM

 Process Control
and Measurement
Process control and measurement implies continuously
changing variable data and/or control methods in an indus-
trial process. Different from discrete (ON/OFF) states, numer-
ic values over a set range are sensed and/or transmitted in
continuous (flow production) or batch (a set quantity or out-
put) processing. Some of the most common variables used
for process control are pressure, flow, level and temperature.

Pressure Process Control

Pressure sensing devices measure pressure at a specific point in the process, used for
monitoring and/or transmitting the measured value to a control device/system that may
perform functions such as starting/stopping or opening/closing, or modulating an analog
output that operates a valve to regulate the pressure.

• Pressure Sensors: Pressure/Vacuum sensors monitor relative system pressure • Pressure Gauges: Pressure gauges are simple display devices for industrial and com-
in many process applications, as well as for hydraulics and pneumatics. Pressure mercial applications. Mechanical dial pressure gauges use Bourdon tube sensing el-
switches typically provide simple setpoint-tripped output signals, while pressure ements; digital pressure gauges can offer enhanced functionality. Differential gauges
transmitters provide absolute, gauge or differential analog readings over wide mea- measure and display the pressure difference between two points. Certain models can
suring ranges. provide a signal to tie to control devices or systems.

• Current to Pneumatic (I/P) Transducers: I/P transducers are electro-pneumatic devic- • Potable Water Regulators: Purpose-built water regulators are compact food-grade
es that, with a 4-20mA input signal (I) and a high-pressure air supply, provide precisely units that provide economical, high-performance pressure regulation of drinkable
regulated air pressure output (P). I/P transducers offer reliable, repeatable operation of water. The highly sensitive diaphragm-operated design delivers accurate down-
pneumatic valve positioners/actuators, cylinders, web tensioners, clutches and brakes. stream pressure and the molded rubber supply valve provides precise regulation
while helping to prevent leakage.

0719-16pager-process_instrumentation-FONTS.indd 2 6/27/19 2:23 PM

 Flow Process Control Go to http://go2adc.com/flow-vid
Flow sensing devices measure the flow rate (volume per unit of time) and/or consumption for a short video on How Do
(totalized flow) of liquid traveling through a system, used for monitoring and/or transmit- Magnetic Inductive Flow Meters Work?
ting the measured value to a control device/system that performs functions such as adjust-
ing the position of a valve, or starting and stopping pumps.

• Flow Sensors: Flow switches monitor liquid media to provide reliable flow detection,
supplying a discrete switch output; transmitters use differential pressure sensing prin-
ciples to provide precise flow measurement, and supply an analog output proportional
to flow rate as gallons per minute.

• Magnetic-inductive flow meters (magmeters): Magmeters use electromagnetic in-

duction principles to reliably detect the flow rate of conductive media such as indus-
trial water, drinking water, water-based coolants, water glycol mixtures, and salt water.

www.AutomationDirect.com 1-800-633-0405

0719-16pager-process_instrumentation-FONTS.indd 3 6/27/19 2:23 PM

 Level Process Control
Level sensors monitor the level of liquids, pellets, powders, and other similar products in
tanks and process systems. The measurement can be used for monitoring purposes or to
control a process. Integrated level controllers can sense level and operate alarms, pumps,
valves and other industrial equipment. A variety of sensing technologies are available, in-
cluding contact and non-contact methods. Choose the sensing technology best suited for
the material being monitored.

• Float Level Switches: Low-cost float switches provide single-point monitoring of liq-
uid level in industrial applications. Powerful permanent magnets within the float actu-
ate a highly reliable and repeatable hermetically sealed reed switch as the float rises
and lowers with liquid level. A variety of material construction and mounting styles
offer compatibility with many liquids, temperature ranges and system pressures.

• Submersible Level Sensors: Submersible sensors provide continuous liquid level

measurement by sensing the hydrostatic pressure produced by the height of liquid
above the sensor. These sensors typically provide a current output signal correspond-
ing to their specific pressure sensing range.

• Ultrasonic Level Sensors: Ultrasonic sensors emit a sound impulse and measure the
elapsed time of the echo from a detected object or material. These types of sensors
can operate as downward facing, non-contact level sensors. Models with discrete
outputs will indicate the presence of the material within the sensing range; distance
sensing models with analog outputs can indicate the material’s relative level within • Vibrating Fork Switches: Vibrating fork switches use a harmonic vibrating frequency
the sensing range. which is reduced when the fork contacts the liquid being monitored. The frequency
reduction indicates the presence of the liquid and the switch sends a signal to the
• Capacitive Level Sensors: Capacitive sensors are useful for detecting the level of sol- control unit. These switches provide reliable level detection of dirty liquids that coat,
ids such as plastic pellets, or water-based conductive liquids. These devices output scale or foam such as wastewater, diluted caustic soda and light oils. They can be
a discrete signal when the presence of material is detected within the sensing range. mounted through-the-wall or inside a tank as high- or low-level indicators.

0719-16pager-process_instrumentation-FONTS.indd 4 6/27/19 2:23 PM

 Ultrasonic wave
increases in diameter
as the wave travels
away from the sensor

Inexpensive
tilt switches provide
reliable level detection
in open vessels
Go to http://go2adc.com/ultra-vid
for a short video on Ultrasonic Liquid Level Sensors

Float T

Examp
opert

Examp
opera

Switch

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0719-16pager-process_instrumentation-FONTS.indd 5 6/27/19 2:23 PM

 Go to http://go2adc.com/rtd-vid
for a short video on RTD vs Thermocouple: Temperature Sensors

Go to http://go2adc.com/probe-vid
for a short video on Temperature Probe Styles

Go to http://go2adc.com/temphh-vid
for a short video on Temperature Sensing
Helpful Hints

0719-16pager-process_instrumentation-FONTS.indd 6 6/27/19 2:23 PM

 • Thermocouple Sensing Elements/Probes: A thermocouple consists of two metallic
probes made of different materials. These two metals are joined together at one end.
When the joined end heats up, a small current is generated at the other end where
the metals are not joined. Wires connected to the separated end transmit the current
to an electrical sensing device, which can calculate the temperature based on the
type of sensor material and current level. Some advantages of thermocouple sensors
include the ability to measure a wide range of temperature, shock and vibration re-
sistance, and fast response time.

• RTD Sensing Elements/Probes: RTD temperature sensors measure the chang-

es in resistance of a metal as the temperature of the metal changes. To accom-
plish this, a small electrical current is applied to the metal probe or sensor and
as the current travels through the metal, a wire provides a connection to this
current. Temperature changes in this metal will increase or decrease resis-
tance, which in turn will affect the current as it travels through the metal. A sens-
ing unit receiving this current signal can calculate the temperature based on
the changes between the injected current and the received current. The main
advantage of an RTD sensor is more precise and stable temperature readings.

• Temperature Switches and Transmitters: Switches with discrete out-

Temperature Process Control puts typically provide simple setpoint-tripped output signals, while tem-
Temperature measuring devices sense temperature at a specific point or area and provide perature transmitters provide analog readings over wide measuring ranges.
a signal for monitoring or control. Temperature transmitters receive the signal (or have an
integral sensor) and convert it to an output more typically compatible with industrial mon- • Temperature Controllers: Temperature process control units read the signal from a
itoring or control devices. Temperature switches integrate sensing and a setpoint-tripped temperature device, such as a thermocouple or RTD, and maintain a setpoint via an
output; controllers combine sensing and control of the variable in one unit. output signal (relay, voltage pulse, current, or linear voltage) to a controlled device,
using modes such as simple ON/OFF, full PID closed-loop control, special Ramp/Soak
• Temperature Sensing: Sensing devices typically supply an electrical signal profiles, or Manual operation
corresponding to temperature. The most common sensing methods include ther-
mocouples and resistance temperature devices (RTD). Both are specialty metal wire • Thermometers: Thermometer gauges are simple devices that measure temperature
devices providing low-level current signals that can be connected directly to a temperature at a specific point using a bi-metallic sensing element with high accuracy. Dials with
sensor; either may need to be extended or amplified to be transmitted longer distances. dual scales provides instant reading of degrees in both Fahrenheit and Celsius, which
helps reduce operator reading errors.

www.AutomationDirect.com 1-800-633-0405

0719-16pager-process_instrumentation-FONTS.indd 7 6/27/19 2:23 PM

 • Digital Panel Meters: Panel meters accept a wide variety of process in-
Other Process Control Devices
Other devices used for process control systems include displays for monitoring process puts and display measured values from devices such as load cells, potenti-
values, signal conditioners, and process valves. ometers, and temperature sensors. Models with outputs can provide alarm
relays, analog signal re-transmission, and sensor excitation voltage.

• Graphical Panel Meters: These meters measure voltage, current or fre-

quency and provide analog meter-style visual readings as well as accurate
numeric formats.

• Signal Conditioners: Signal conditioners, transmitters and optical isola-

tors are used in process control systems to solve ground loop problems, iso-
late noise issues, convert signals to desired levels and types, and to allow
longer cable runs. Limit alarms monitor analog inputs and provide low limit,
high limit, or other discrete output indications based on the input value.

• Timer Relays / Counters / Tachometers: Timer relays provide simple

time-based control, with multiple modes and adjustable timing ranges, dis-
crete outputs, and a mechanical or electronic display. Multi-function units
combine features of a digital counter, timer, and tachometer.

• Solenoid Process Valves: Pipeline valves allow ON/OFF flow control

and/or mixing and diverting of process media such as air, oil, inert gas, wa-
ter, and even some caustic materials.

• Solenoid Separated Process Valve: Media-separated two-port dis-

crete pipeline valves allow ON/OFF flow control of gases or fluids where
the (metal) working components of the valves never come into contact with
the process media.

• Power Monitors: Power meters are highly accurate devices that measure
standard power parameters, plus metering and harmonics.

0719-16pager-process_instrumentation-FONTS.indd 8 6/27/19 2:23 PM

 www.AutomationDirect.com

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0719-16pager-process_instrumentation-FONTS.indd 9 6/27/19 2:23 PM

 If it’s in your cabinet . . .
. . . it’s online at AutomationDirect.com CPU and I/O
Comparison
AutomationDirect
CLICK
AutomationDirect
Do-more! (BRX)
AutomationDirect
Productivity2000
Allen-Bradley
CompactLogix

Base (if required) N/A N/A $72.00 N/A

N/A N/A P2-04B N/A

• Productivity1000® micro-modular PLCs Power Supply $40.50 N/A $72.00 $508.00

C0-01AC N/A P2-01AC 1769-PA4

• Productivity2000® micro-modular PLCs CPU $142.00 $489.00 $264.00 $7,600.00

C0-10ARE-D (Ethernet built in) BX-DM1E-36ER3 (Ethernet built in) P2-550 (Ethernet built in) 1768-L45 (Serial port only)
• Productivity3000® modular PLCs
16 AC Inputs $41.00 $60.00 $109.00 $325.00
• Do-more® BRX®, H2 and T1H series PLCs C0-08NA (8-point AC Input)* BX-16NA P2-16NA 1769-IA16

• CLICK® micro brick PLCs 16 24VDC Inputs $46.00 $0.00 $72.00 $277.00
C0-16ND3 Included with CPU P2-16NE3 1769-IQ16

• Numerous I/O expansion modules 8 Relay Outputs $41.50 $0.00 $53.00 $327.00
available including discrete, analog, C0-08TR Included with CPU P2-08TRS 1769-OW8I

temperature and high-speed 8 Analog Input

Channels (mA) $92.00 x 2 $187.00 $206.00 $895.00
BX-08AD-1 P2-08AD-1 1769-IF8
(depending on model) (2) C0-04AD-1

Total System
• Think & Do® PC control software Price $487.00 $736.00 $848.00 $9,932.00

• DirectLOGIC® components still available *C0-08NA used in conjunction with eight AC inputs on CPU gives the 16 points needed
for maintaining legacy systems. All prices are U.S. published prices. AutomationDirect prices as of 6/26/2019. Allen-Bradley prices taken from www.radwell.comradwell.com 4/16/2019.

Programmable
Controllers
• C-more® operator interface HMI touch
panels in various sizes up to 15 inches
with wide screen options available
• C-more Micro®-graphic text and touch
panels
Distributed I/O with - 3, 4, and 6-inch models available
Modbus® TCP, EtherNet/IP, starting at only $98
Modbus RTU, DeviceNET • ViewMarq® LED message displays
and Profibus® support
• ATLAS® industrial monitors

Universal HMI/Operator
Field I/O Interface
0719-16pager-process_instrumentation-FONTS.indd 10 6/27/19 2:23 PM
 • IronHorse® general purpose
AC motors up to 300hp
• Stainless steel AC motors
• DC motors up to 2hp
• DURApulse® variable frequency
AC drives up to 300hp • Marathon® inverter duty AC
motors up to 100hp
• WEG CFW300 AC drives up to 5hp
• Open Drip Proof and 4-in-1
• IronHorse® DC drives up to 3hp Marathon Motors
• Cost-effective GS2 series VFDs up to 10hp • Compressor duty AC motors
• Drive accessories up to 5hp
• Soft starters up to 480A • Motor controls and

Motors and
contactors up to 300hp

Motor Controls
Voted #1 mid-size company
AC and DC Drives GO! to work for in Atlanta:
• Temperature
www.automationdirect.com/workplace
controllers
• Digital panel meters
What our current customers think: • Temperature sensors
GO! www.automationdirect.com/reviews and transmitters
• Pressure sensors and gauges
• Level sensors and controllers
• Flow sensors
• Signal conditioners
• Free PLC programming • Free Micro HMI
software (download) programming • Pipeline valves
• System configuration software (download) • Current to pneumatic (I/P)
transducers
• Free motion control
software (download) • Timer relays, counters
and tachometers
Process
Software
www.AutomationDirect.com 1-800-633-0405

0719-16pager-process_instrumentation-FONTS.indd 11 6/27/19 2:23 PM

 Donald in
STUDIO CITY, CA
wrote:
• Electro-mechanical relays
“Automation Direct is now
• Reer MOSAIC safety controllers • Solid state relays
my one stop shop for all
• IDEM® and Dold® safety relays • Relay sockets
pneumatic components. and accessories
• Speed/Standstill safety relay They have the biggest selection
modules • Timer relays
of parts, and the shipping is
• Magnetic safety switches • Counters
prompt. No more searching the
• Magnetic coded safety switches • Tachometers
internet for this part and that
• RFID coded safety switches • Motor control relays
part. Highly recommended!”
• Light curtains • Force guided relays
• Safety relays
• Trapped key interlocks  Samuel in
Safety • Safety mats and edges QUEBEC, QC Relays & Timers
wrote :
“The shipping was very quick
and you have everything. Will • Wera screwdrivers
and torque tools
buy there again”
• Wera wrenches, ratchets
and sockets
• Knipex® pliers, stripping
• Worm gearboxes Phillip in and crimping tools
• Helical gearboxes CAPE CANAVERAL, FL • Cable tie tools
• Precision gearboxes wrote: • Hole cutting tools
• Shaft mount gearboxes “PLC system components • RUKO grinders and burrs
• Timing belts and pulleys that I have purchased from • SapiSelco® wire ties
• Couplings and bushings AutomationDirect were easy • AutomationDirect
• Shafting and shaft supports to configure and have function interchangeable die
• igus polymer bearings well in the desired application! crimping tool, self-
adjusting crimper and
Customer support has been
Power Transmission excellent.” Tools rotatable die crimpers

0719-16pager-process_instrumentation-FONTS.indd 12 6/27/19 2:23 PM

 AutomationDirect
Servo Price/Part Number
Allen-Bradley
Systems Price/Part Number

Digital Servo Drive $483.00

SVA-2040
$1,418.00
2098-DSD-005
• SureStep® drives and
NEMA motors
100W Servo Motor
with connectorized Leads
$322.00
SVL-201
$643.65
TLY-A130T-HK62AA
• SureServo® drives
and motors, up to 3kW
Breakout Board Kit for $82.00
ZL-SVC-CBL50 +
$316.05 • Encoders
CN1 Control Interface 2090-U3BK-D4401 • Linear slides 
ZL-RTB50

• Stepper and
10’ Motor
Feedback Cable
$51.00 $96.68 servo gearboxes
Motion Control
SVC-EFL-010 2090-CFBM6DF-CBAA03

10’ Motor
Power Cable
$31.00 $109.00
2090-CPBM6DF-16AA03
SVC-PFL-010

Configuration Software FREE $85.02

2098-UWCPRG • Proximity sensors • Pressure sensors
SV-PRO*

• Photoelectric sensors and gauges

• Limit switches • Temperature sensors,
*SureServo Pro software is FREE when downloaded and is also available for $9.00 on a CD switches, transmit-
• Precision limit ters and thermom-
Complete 1-axis 100W System $969.00 $2,668.40 switches eters
All prices are U.S. list prices, AutomationDirect prices as of 6/26/2019.
The Allen-Bradley 100W system consists of part numbers shown in table above with prices from • NEMA limit switches • Liquid level
www.wernerelectric.com, www.todaycomponents.com 4/25/2019.
• Laser sensors sensors
George in HOLLAND, MI wrote: • Color and contrast • Flow sensors
sensors • Ultrasonic
“I have come to trust AutomationDirect will provide a quality product
• Area sensors sensors
and service. Questions before, during, and after the sale are addressed
• Encoders • Fork sensors
in a professional and courteous manner. Technical Support is great.
I do not hesitate in reaching out to them for assistance. There have • Current and
been occasions when follow-up calls were made, because of the Sensors voltage sensors

complexity of the situation or my lack of experience with a product.”

www.AutomationDirect.com 1-800-633-0405

0719-16pager-process_instrumentation-FONTS.indd 13 6/27/19 2:23 PM

 • Acme Electric®, Hammond and
Jefferson Electric® transformers
• Rhino® DC power supplies and
• Industrial managed and converters
unmanaged Ethernet switches • Mersen surge protectors
• Modbus gateways • Roxburgh and Eaton line filters and
• Network adapters/ converters surge protectors
• Ethernet cables • Roxburgh power outlets
• ACME Electric encapsulated
• VPN routers and cloud services transformers
for secure remote access
• Edison® power distribution blocks
• Power over Ethernet (PoE)
switches • Bryant® electrical plugs, connectors
and receptacles, and other wiring
D Power Products devices
• AcuAMP® AC current transformers

Communications • Socomec multifunction power

meters

Pushbuttons, • Tubing, hose and fittings

in a wide variety of
• Trumeter graphical panel meters

Switches and Lights configurations

• KILLARK® hazardous location control stations • Air cylinders and position • Regulators
• IDEM emergency stops switches • Solenoid valves
• Fuji®, Schmersal and Eaton metal/ • Solenoid valves • Hand valves
plastic 22 and 30mm pilot devices • Modular solenoid valves • Check valves
• IP69K-rated selector switches, pilot devices (Ethernet or hardwired)
• Push-to-connect water
and pushbuttons from Schmersal • Air preparation and air relief fittings
• WERMA audible devices and visual signals valves
• Lead-free brass fittings
• WERMA and Patlite stacklights • Pushbutton valves
• Tubing
• IP69K-rated Patlite stacklights • Total Air Prep (TAP)
all-in-one units • Hose
• Patlite signal towers and LED lighting
• Rotary actuators • Hose clamps
• Foot switches and grippers

Pneumatics
• Pressure switches, transmit-
ters, and transducers Water (Potable) Components

0719-16pager-process_instrumentation-FONTS.indd 14 6/27/19 2:23 PM

 • Electrical hook-up wire / • Wire end connectors
building wire cable glands, connec-
• Eaton UL 489 miniature
• Konnect-It® and tors and fittings
circuit breakers
DINnectors® terminal • ZIPport® connectors
• Fuji UL 489 molded case
block systems • Multi-wire connectors
circuit breakers
• Edison power • Sensor cables
• Eaton UL1077
distribution blocks
supplementary protectors • DYMO XTL Label
• Bryant power wiring Makers and Labels All of our cable is now
• Edison fuses, fuse holders
devices available cut to your specified
and fuse blocks • General, latching,
• Wire duct and tubing length so you can eliminate
• Socomec, Gladiator® UV resistant, releas- waste and purchase
and Bryant® disconnect able, mounting head, only what you need -
switches identification, and plus it’s cut and shipped
metal-detectable the same day!
• Bryant UL 508 manual
motor controllers Terminal Blocks cable ties
Types of cable we offer:
and Wiring • Flexible portable cord
Circuit Protection • Over 2,400 NEMA rated • Bulk data cable
enclosures to choose from (RS232/ RS422/ RS485)
• Stainless steel, carbon steel • Flexible control (tray) cable
and aluminum enclosures
AutomationDirect from Hubbell-Wiegmann® • Variable frequency drive
Hoffman (VFD) Cable
Enclosures Hubbell/Wiegmann
Price/Part Number Price/Part Number • Fiberglass and polycarbonate
• Instrumentation cable
enclosures from Attabox
NEMA 1 wall mount
24 x 24 x 08”
$218.00
N1C242408LP
$343.81
A-24N24BLP • Polycarbonate enclosures • Continuous flexing
from Integra control cable
NEMA 12 wall mount
20 x 16 x 08”
$284.00 $477.51 • Continuous flexing motor
N12201608 A-201608LP
• Thermoplastic ABS enclosures
NEMA 12 free-standing $1,927.00 $2,813.35 from AutomationDirect supply cable
mount 60 x 60 x12” N12606012 A-606012LP
• Custom cut-out • Continuous flexing
NEMA 4 wall mount
20 x 20 x 06”
$389.00 $614.50 enclosures industrial Ethernet cable
N4202006 A-20H20ALP

NEMA 4X wall mount $765.00 $1,447.97 • Heating, cooling and • Control and signaling cable
20 x 20 x 06” SSN4202006 A-20H2006SSLP
climate control • Bulk sensor/actuator cable
NEMA 4/12 wall mount $370.00 $602.87
36 x 24 x 08” N412362408C C-SD36248 • Lighting

*All prices are U.S. published prices. AutomationDirect prices as of 6/26/2019. Hoffman prices are taken from www.alliedelec.com 4/30/2019.
Prices may vary by dealer. Many other part numbers are available from all vendors.
Enclosures
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0719-16pager-process_instrumentation-FONTS.indd 15 6/27/19 2:23 PM

 AutomationDirect.com
Engineering, Development and Research AutomationDirect.com HQ campus and warehouses

AutomationDirect
3505 Hutchinson Rd
Cumming GA 30040

• Honest up-front pricing (no gimmicks)

• Quick delivery - order today, it ships fast!
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multiple huge warehouses and speedy logistics team.
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AutomationDirect.com has been a leader in providing affordable,

quality industrial control products to the U.S. and Canada for more
than two and half decades.
As a privately-held efficiently run company, we take pride in serving
our customers the way they want to be served - honestly and fairly.
We do everything we can to accomplish this day in and day out.

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0719-16pager-process_instrumentation-FONTS.indd 16 6/27/19 2:23 PM