How to choose a signaling format that makes machine conditions clearer without adding unnecessary hardware or integration complexity.
A machine can be operating normally, waiting for material, approaching a maintenance interval or stopped by a fault. If all these conditions are reduced to one green light and one red light, operators receive too little information to respond efficiently. Modern status indication therefore needs to communicate more states, remain visible from the relevant working positions and fit the electrical and mechanical design of the machine.
Pfannenberg has expanded the available options for this task with IO-Link versions of several established signaling products. The new IO-Link variants add digital control and parameterisation to compact RGB status lights, combined audible and visual signaling, and the modular BR 50 signal tower. Conventional M12-connected versions of selected INTENSE products remain available when central parameterisation and IO-Link communication are not required. Machine builders can therefore select the control method that suits the application without changing the basic form factor of the indicator.
A status indicator is an interface between the machine and the people working around it. Its purpose is not simply to produce light. It must make the condition of the equipment understandable at the moment when an operator, maintenance technician or supervisor needs that information.
The signaling concept can become unclear when different machine conditions share the same colour, when indicators are hidden behind guards or frames, or when a tower is too tall for the available installation space. Another common limitation is inflexible wiring. If every colour and pattern needs its own controller output, adding a new status can require electrical and software changes.
RGB LED signaling devices address part of this problem because one light source can display several colours. IO-Link extends that flexibility by allowing supported colours, brightness levels, flashing frequencies and signaling modes to be parameterised through the automation system. The appropriate solution still depends on the viewing direction, required signal area, need for sound, mounting position and environmental conditions.
Before selecting a machine status light, define what the device must communicate. Normal production, setup, waiting, material shortage, operator call, maintenance request and fault conditions may require different visual states. A limited and consistent signaling scheme is generally clearer than using every available colour and pattern.
Next, determine where the signal must be visible. A bar installed on a machine profile creates a different viewing effect from a dome mounted on top of an enclosure. A combined sounder and LED light is appropriate where visual indication alone may not attract attention. A modular tower is useful when distinct physical stages or an additional audible module are required.
The Pfannenberg portfolio supports these different tasks through four product concepts: the INTENSE BAR S and BAR M, the INTENSE DOME 50, the PA L 1-R RGB combined sounder and light, and IO-Link modules for the BR 50 signal tower.
The INTENSE BAR S, INTENSE BAR M and INTENSE DOME 50 are available in both a conventional M12-connected RGB version and an IO-Link version. M12 describes the connector, not the communication method. The conventional version is suitable when the required states can be controlled directly and central parameterisation or IO-Link communication is not needed. It offers the same compact design without requiring an IO-Link master.
The IO-Link version is more appropriate when signaling behaviour must be configured centrally, reused across machine variants or changed without rewiring individual functions. On the supported INTENSE devices, Pfannenberg specifies parameterisation of colours, flashing frequencies and signaling modes. Brightness adjustment is also identified for the IO-Link BAR versions.
IO-Link should not be selected only because it is available. The engineering team should confirm the master port, power requirements, IODD integration and required process data. Where an IO-Link infrastructure is already used for sensors and actuators, adding signaling devices can provide a consistent field-level architecture. Where only a few fixed states are needed, conventional control through an M12 connection may remain the more direct solution.
The INTENSE BAR S is intended for applications where a clearly visible status light must fit into a compact machine design. It uses an RGB LED light surface, allowing several machine conditions to be represented by one device. Front mounting with M6 cylinder screws makes the bar particularly relevant for T-slot profile systems and machine frames.
Pfannenberg describes the light surface as diffuse, with 360-degree perceptibility. The diffuser is made from impact-resistant, shatterproof polycarbonate and the housing from aluminium. An M12 connector is used for the electrical connection. These features suit equipment where a signal tower would occupy too much space or be exposed to impact.
The BAR S is available under product number 22015808097 with conventional control through an M12 connection and under product number 22015808099 with IO-Link. Both use 24 V DC. The conventional version has a specified operating range of 21 to 27 V DC and a specified current consumption of 0.040 A. The IO-Link version has an operating range of 21 to 30 V DC and a specified current consumption of 0.085 A.
The INTENSE BAR M uses the same design principle in a longer format. It is intended for machines where the status indication requires a larger illuminated area or must be visible across a wider part of the installation. Like the BAR S, it combines an RGB LED light surface with front mounting, an aluminium housing, a polycarbonate diffuser and an M12 connection.
The choice between the S and M versions should therefore be based primarily on the available installation space, intended viewing positions and required illuminated area. A compact workstation or small machine module may suit the BAR S. A longer machine section, access point or conveyor position may benefit from the increased light surface of the BAR M.
Product number 22015808297 is the conventional M12-connected version, while product number 22015808299 is the IO-Link version. Both operate at 24 V DC. Pfannenberg specifies an operating range of 21 to 27 V DC and a current consumption of 0.16 A for the conventional version, compared with 21 to 30 V DC and 0.2 A for the IO-Link version.
A bar is not suitable for every machine. When the indicator must be mounted on top of an enclosure or in a position where the signal should be recognised from different directions, a compact dome format can be more appropriate. The INTENSE DOME 50 provides RGB status indication in a low-profile housing with an M12 connection.
The format is useful where a full multi-stage tower is unnecessary or where installation height is limited. One RGB device can display different machine states without stacking separate coloured modules. The supplied product information specifies an IP67 enclosure rating for the DOME 50. The protection rating of the complete installation also depends on correct mounting and connection.
Product number 22016808597 is the conventional 24 V RGB version with an M12 connection. Product number 22016808599 is the IO-Link version, which supports central parameterisation of colours, flashing frequencies and signaling modes.
Visual indication is effective only when the relevant person can see it. In production areas with restricted sightlines or a high ambient noise level, an audible signal may also be required to attract attention. The PA L 1-R combines an RGB LED light with a radial sounder in one housing.
Pfannenberg specifies a maximum sound pressure level of 105 dB(A). The PA L 1-R supports selectable visual signaling modes, including continuous, blinking, flashing and rotating light effects. Tone and volume options allow the acoustic output to be adapted to the application. The top-mounted design provides 360-degree perceptibility, while the acoustic and visual functions share one mounting position.
The RGB IO-Link variant, product number 23383808099, operates at 24 V DC and enables parameterisation of the signaling modes. This version is relevant where one device must communicate normal operating states visually and draw attention to higher-priority conditions acoustically.
A sounder must always be selected with the ambient noise, required coverage and applicable signaling requirements in mind. A high maximum dB(A) value alone does not prove that a signal will be perceived correctly throughout the intended area.
PA L 1-R RGB IO-Link (23383808099)
Some machines require separate physical stages instead of one RGB light surface. A modular tower can show several conditions simultaneously, preserve an established colour arrangement or combine visual modules with an audible element. The BR 50 is a slim modular signal tower designed for this type of application.
Pfannenberg states that up to five modules can be combined in the BR 50 system. Depending on the configuration, continuous LED, blinking, flashing and audible modules are available. Mechanical and electronic decoupling contributes to resistance against vibration, and the tower can be mounted directly or with different stand and bracket arrangements.
IO-Link control is available through two 24 V DC module variants. Product number 28250988000 combines the BR 50 IO-Link module with an M12 base and is specified for a maximum of four stages. Product number 28250998000 is the IO-Link module without the base, allowing it to be used in a compatible BR 50 configuration. The supplied product information specifies IP54 for both variants.
The separate BR 50 sounder module, product number 28250818000, can be added when an acoustic output is required. It is specified at 96 dB(A), 24 V DC and IP65. It is an expansion component within the configured tower, not a standalone IO-Link product.
The correct device is determined by the signaling task and installation conditions, not simply by the number of available colours. The following selection logic provides a practical starting point.
Use the compact BAR S when the indicator must be integrated into a machine frame or T-slot profile and a slim illuminated surface provides sufficient visibility.
Use the BAR M when the status should be noticeable across a larger section of the machine while retaining the same profile-mounted design principle.
Use the DOME 50 when the signal needs to be recognisable from different directions, but a multi-level signal tower is unnecessary or too tall.
Use the combined sounder and RGB light when a visual state alone may not attract attention or when a higher-priority warning requires an acoustic component.
Use the BR 50 when separate modules, simultaneous states, established tower conventions or an optional sounder are required. The IO-Link module makes this modular format compatible with an IO-Link control concept.
Visibility must be assessed from the intended operator and maintenance positions. Mounting height, obstructions, ambient light and the meaning of each colour or pattern should be considered. For acoustic signaling, ambient noise and the required coverage area also affect product selection.
Confirm the supply voltage, current consumption, M12 pin assignment, IP rating and mounting arrangement for the exact product number. For IO-Link variants, also verify the master port, power budget, IODD and PLC integration. The conventional and IO-Link versions are not electrically identical, so data from one variant should not be applied to the other.
Finally, distinguish operational status indication from a safety function. A configurable signal light can improve communication, but IO-Link or RGB capability does not by itself provide a required Performance Level or SIL. Operational signaling does not replace a protective function or any safety-related indication required by the machine risk assessment. Safety-related functions must be implemented with suitable components and system architecture.
The Pfannenberg portfolio allows machine builders to match the status indicator to the signaling task and installation conditions. The INTENSE bars provide profile-mounted RGB indication, the DOME 50 offers a compact top-mounted format, the PA L 1-R combines light and sound, and the BR 50 retains the flexibility of a modular tower.
For the INTENSE family, the choice between conventional control through an M12 connection and IO-Link makes it possible to select the required level of integration. Fixed machine states do not always require IO-Link. Applications that benefit from central parameterisation, reusable configurations and digitally controlled signaling modes can use the new IO-Link variants.
Need help selecting a machine signaling solution?
The appropriate device depends on the required visibility, mounting position, available space, environmental conditions and preferred control method. View the Pfannenberg signaling devices available from Machine Safety Shop or contact our technical specialists for assistance with product selection.
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Use this table for editorial verification and product linking. Technical values must be checked against the final webshop data for each product number.
| Product number | Product | Configuration | Control |
|---|---|---|---|
| 22015808097 | INTENSE BAR S | 24 V RGB, M12 | Conventional |
| 22015808099 | INTENSE BAR S | 24 V RGB, M12 | IO-Link |
| 22015808297 | INTENSE BAR M | 24 V RGB, M12 | Conventional |
| 22015808299 | INTENSE BAR M | 24 V RGB, M12 | IO-Link |
| 22016808597 | INTENSE DOME 50 | 24 V RGB, M12 | Conventional |
| 22016808599 | INTENSE DOME 50 | 24 V RGB, M12 | IO-Link |
| 23383808099 | PA L 1-R RGB | 24 V DC, 105 dB(A) | IO-Link |
| 28250988000 | BR 50 module with M12 base | 24 V DC, max. 4 stages | IO-Link |
| 28250998000 | BR 50 module | 24 V DC, for BR 50 configuration | IO-Link |
Source list for technical review. Remove or adapt this section before publication if references are managed separately in the CMS.
Pfannenberg, IO-Link signaling technology overview
Pfannenberg, PA L 1-R product information
Pfannenberg, INTENSE BR 50 product information
Pfannenberg, INTENSE BAR S product information
Pfannenberg, INTENSE BAR M product information
Pfannenberg, INTENSE DOME 50 product information
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