Enhancing Industrial Automation with ProSense DIN Rail Signal Isolators and Temperature Transmitters
- tass peters
- Jan 29
- 3 min read
Industrial automation relies heavily on accurate and reliable signal conditioning to ensure smooth operation, precise control, and effective monitoring. ProSense DIN rail signal isolators and temperature transmitters offer a practical solution designed to meet these needs without inflating costs. These devices provide universal programmable inputs, galvanic isolation, and flexible output options, making them ideal for integrating sensors and signals into PLCs, DCS platforms, and SCADA systems.
This post explores how ProSense modules improve industrial signal conditioning, their key features, and typical applications that benefit from their use.
Why Signal Conditioning Matters in Industrial Automation
Signal conditioning converts raw sensor signals into standardised, noise-free signals that controllers and monitoring systems can interpret accurately. In industrial environments, signals often face interference from electrical noise, voltage spikes, and ground loops. Without proper isolation and conversion, these issues lead to inaccurate readings, equipment malfunction, or even system failures.
ProSense DIN rail signal isolators and temperature transmitters address these challenges by:
Isolating signals electrically to prevent noise and ground loop interference
Converting various sensor inputs into standardised outputs compatible with control systems
Providing stable, accurate measurements over time and temperature changes
This ensures that automation systems receive clean, reliable data for better decision-making and control.
Key Features of ProSense DIN Rail Signal Isolators and Temperature Transmitters
ProSense modules combine versatility, accuracy, and ease of installation in a compact DIN rail form factor. Here are the main features that make them suitable for industrial signal conditioning:
Universal Programmable Inputs
These devices accept a wide range of input signals, including:
Thermocouples (various types)
Resistance Temperature Detectors (RTDs)
Current signals (mA)
Voltage signals (V, mV)
Resistive sensors
This flexibility allows integration with many sensor types without needing separate converters.
Flexible Output Options
ProSense modules offer multiple output formats to match different control and monitoring systems:
Current outputs: 4–20mA, 0–20mA
Voltage outputs: 0–5V, 1–5V, 0–10V
Relay outputs for switching applications
RS485 MODBUS-RTU for digital communication
This variety supports easy connection to PLCs, DCS, SCADA, and other industrial controllers.
High Accuracy and Stability
Accuracy is critical for process control. ProSense devices provide:
±0.2% full scale (FS) accuracy
Ultra-low temperature drift of ≤0.0075% FS per °C
This ensures consistent, precise readings even in fluctuating environmental conditions.
Complete Galvanic Isolation
Each module offers 1.5kVrms isolation between power supply, input, and output. This galvanic isolation:
Protects equipment from voltage surges
Eliminates ground loops
Reduces electrical noise interference
Multiple Input/Output Configurations
Depending on the model, ProSense modules support:
1 input / 1 output
1 input / 2 outputs
2 inputs / 2 outputs
This flexibility helps tailor signal conditioning to specific application needs.
Local Display and Easy Configuration
Many models include LED or optional LCD displays that show process values (PV) and set values (SV). Configuration is straightforward via front keys, enabling quick setup without additional tools.
Slim DIN Rail Design with Pluggable Terminals
The compact design fits neatly into control panels, saving space. Pluggable terminals simplify wiring and maintenance, reducing installation time.
Wide Power Supply Compatibility
ProSense modules operate on:
DC 20–32V power supply
AC 100–260V power supply (depending on model)
This wide range supports various industrial power environments.
Typical Applications for ProSense DIN Rail Modules
ProSense signal isolators and temperature transmitters serve many industrial sectors and use cases:
PLC and DCS Signal Integration
They convert and isolate signals from field sensors to PLCs and distributed control systems, ensuring accurate data flow and protecting controllers from electrical faults.
Temperature Measurement and Conversion
Thermocouples and RTDs are common temperature sensors in industry. ProSense modules convert these signals into standard outputs for process control and monitoring.
Industrial Automation and Process Control
Accurate signal conditioning improves control loop performance, reduces downtime, and enhances product quality in manufacturing and processing plants.
HVAC and Energy Systems
Monitoring temperature, current, and voltage signals in heating, ventilation, air conditioning, and energy management systems helps optimise efficiency and safety.
Building Management Systems
Signal isolators integrate various sensor inputs into centralised control systems for lighting, climate, and security management.
Instrumentation and Monitoring Panels
ProSense modules provide reliable signal conditioning for instrumentation racks, ensuring clean data for analysis and alarms.
Practical Example: Improving Signal Quality in a Manufacturing Plant
A manufacturing plant faced frequent signal errors and equipment trips due to noisy wiring and ground loops in their temperature monitoring system. By installing ProSense DIN rail signal isolators with galvanic isolation and universal inputs, they:
Eliminated ground loop interference
Achieved stable temperature readings from thermocouples
Reduced downtime caused by false alarms
Simplified wiring with pluggable terminals
This upgrade improved process reliability and lowered maintenance costs.
Installation Tips for ProSense DIN Rail Modules
Mount modules on standard 35mm DIN rails inside control panels.
Use shielded cables for sensor wiring to reduce noise.
Ensure proper power supply voltage according to model specifications.
Configure input and output parameters using front panel keys or software if supported.
Verify isolation by checking wiring and grounding practices.
