automation notebook: online technical magazine · 2019-09-06 · automation notebook summer 2011...

www.automationdirect.com/c-more-micro orwww.c-moremicro.com

We squeezed the features of our popular TFT 6-inch C-moreMicro into a 4-inch package for even more value! Takeadvantage of the clear and colorful graphics on the TFTcolor touch screen to create a vibrant and intuitive operatorinterface. Five programmable function keys give you lotsof flexibility. FREE programming software offers thechoice of using many built-in objects, such as buttons, bargraphs and data entry keypads.

Or import your own custom graphics, and save to libraries foruse in multiple projects. Alarm control, recipes and a built-inproject simulator are time-saving tools for more complexapplications. All these features at a competitive price, in arugged and reliable package, give you a sweet HMI for eventhe smallest control system.

* The programming software is free when downloaded from the

AutomationDirect Web site, or the CD-ROM package can be purchased for

$25 (part # EA-MG-PGMSW).

Also Available

Get a big bang for your buck

Popular protocols/devices supported* All AutomationDirect programmable controllers* Modbus® RTU* Allen-Bradley® DF1 half/full duplex, PLC-5®

DF1 and DH485* Siemens PPI* GE Fanuc 90™ -70 and 90-30 SNPX* Omron Host Link and FINS serial* Mitsubishi MELSEC®

Go online for complete list

3-inch touch andnon-touch panels

6-inch STN and TFT touch panels

Optional plug-and-play keypad bezelsfor 3- and 6-inch models

• Mounts in standard 1/4 DIN cutout• 32k Color TFT touch screen display• LED backlight• 320 x 240 resolution• 3.2 MB memory• Mounting variations for key orientation• Five durable function keys with LED indicators• Standard Type B USB programming port• 15-pin serial communications port• Enhanced objects and graphics• Up to 999 screens (dependent on complexity)• Recipes• Built-in project simulator• UL, cUL, CE, NEMA4 and 4X indoor ratings

www.automationdirect.com

1-800-633-0405

Go online or call to get complete information,request your free catalog, or place an order.

Our shipping policies make it easier than ever to order direct from the U.S.!Free standard shipping is available for orders totaling over $300 U.S. (except for orders which require LTL shipping,see Web site for details). Also, save on brokerage fees when shipping standard ground to Canada - you can chooseto allow AutomationDirect to nominate a broker for your shipment for parts shipping via standard ground. Thiscan save you big on brokerage fees. See Web site for details and restrictions -

www.automationdirect.com/canada

3

Automation Notebook Summer 2011 Issue Twenty

www.automationnotebook.com

Contributors Editor’s Note Table of ContentsWe hear in the news every day

about skyrocketing gasoline prices. Asfuel prices continue to soar, we also hearof new ways people are conserving.More people are telecommuting moreoften to save money. Others are findingmore fuel efficient modes of transporta-tion. They take the bus or train moreoften. Others choose to carpool. Manyare buying alternative fuel vehicles.Whether it’s biodiesel or electric energy,if it reduces the amount of gasolinebeing used, we’re all becoming moreopen to the idea of not only savingmoney but also saving our energyresources. In what ways are you con-serving?

Do any of your energy-savingapplications use AutomationDirectproducts? We’d love to hear aboutthem. Drop us a line explaining yourindustrial processes. You never know,your story just might find its way ontothe pages of a future issue ofAutomation NOTEBOOK.

This issue of NOTEBOOK isfilled with interesting articles and bitsof information that just might inspireyou to try something differently. Wehave lots of information regarding ournewest products. An informative appli-cation story shows us how a theatergroup in Chicago used pneumaticcylinders to tell their story. Our StudentSpotlight section provides details abouta group of kids using our products tohelp capture energy from the sun.

There’s a lot more, including theever-popular Breakroom. Test your witsto see if you can solve the mind teasers.But, most of all sit back, relax, and turnthe page…

TJ JohnsCoordinating [email protected]

New Product Focus 4Dold safety relays now available

Product Snapshots 6AutomationDirect Renews Partnershipwith Kepware for Communications,Encapsulated transformers lineexpanded, Inductive DC proximitysensors, Compact fusible switches available, Current sensing line expandswith ground fault sensors and DCcurrent transducers and switches,Photoelectric sensor line expanded,65mm mushroom head metal pushbuttons now available

Feature Story 10Upgrading Pump Stations withPLCs: When relays and timercircuits get old, they cause problems. Replacing them with PLCs keeps pumps running smoothly.

System Integrator Corner 15UL 508A Certified Panel Shops

User Solutions 16House Theater of Chicago

Tech Thread 18PLC-Based Temperature Control:PLC works where single looptemperature controllers fell short

Business Notes 22Goings-on in the industry

Tech Brief 24Top 10 Tips: Specifying VFDs(Part one of a two-part series)

Student Spotlight 27Multi-mirror solar array

Break Room 31BrainTeasers

Publisher Tina Gable

Managing Editor Joan Welty

Coordinating Editor TJ Johns

Design Manager Justin Stegall

Contributing WritersTim Hanes

Joe KimbrellHenry Palechek

Ryan Poethke Chip McDaniel

Tim Roberts

CONTACTSAutomationdirect.com Inc.3505 Hutchinson RoadCumming, GA 30040

Phone . . . . . . . . . . 1-800-633-0405or 1-770-889-2858

Fax . . . . . . . . . . . . . 1-770-889-7876

Monday - Friday 9 a.m. to 6:00 p.m. EST

www.automationdirect.comCopyright 2011, Automationdirect.com Incorporated/AllRights Reserved. No part of this publication shall becopied, reproduced, or transmitted in any way withoutthe prior, written consent of Automationdirect.comIncorporated. Automationdirect retains the exclusiverights to all information included in this document.

If you are a non-subscriber andwould like to be included in the next mailing of AutomationNotebook,please visit:

http://www.automationnotebook.com/freestuff.html on the AutomationNotebook Web site, and complete thedetails. You can also request FREE stuff,including our catalog and our CD-ROMfeaturing the entire catalog and demosoftware. If you provide your emailaddress, we will send news and productinformation from time to time as well.

For those who prefer to speak withus in person, please call 1-800-633-0405x1845. Thanks for your interest, and welook forward to hearing from you.

Your guide to practical products, technologies and applications

New Product Focus

4

Dold safety relays nowavailable

utomationDirect’s safety product line now includesDold safety relay devices for

use in industrial applications. Used inconjunction with our light curtains and safety limit switches, theserelays offer reliable control for machinesafety applications.

LG5924 Series relays are single-channel E-stop relays designed to protect people and machines in applica-tions with emergency stop buttons.Available with 24 VDC, 110 VAC, and230 VAC coil voltages, the Category 2-rated relays are equipped with internalpositive temperature coefficient resistorshort circuit protection. Output configuration options include either twonormally-open contacts, or three normally-open and one normally-closedcontact. The normally-open contacts aresafety contacts. Prices for LG5924 seriessafety relays start at $88.

LG5925 Series relays are dual-channel E-stop/safety gate relaysdesigned for applications with emergency stop buttons and safetygates. Available with 24 VAC/DC, 110VAC, and 230 VAC coil voltages, theCategory 4-rated relays are equippedwith internal positive temperature coefficient resistor short circuit and voltage-dependent resistor overvoltageprotection. Designed with three normally-open positive guided safetycontacts and one normally-closed monitoring contact, LG5925 relays provide a feedback circuit to monitor external contactors used for reinforce-ment of contacts, and feature monitoredmanual restart. Prices for LG5925 seriessafety relays start at $115.

The BH5928 Series relays are alsodesigned for applications with emergency stops and safety gates. Thisdual-channel series provides one or twochannels which can be monitored withthe time delay function. Output configuration options include eitherthree normally-open time delay positiveguided safety contacts, or two instantaneous positive guided safetycontacts and one normally-closedinstantaneous monitoring contact.Three time delay options with potentiometer adjustment are available(depending on model) ranging from 0.1to 30 seconds. The 24 VDC Category 4relays are equipped with internal positive temperature coefficient resistorshort circuit and voltage-dependentresistor overvoltage protection, and canbe wired with or without cross-fail mon-itoring in the E-stop loop. Prices for theBH5928 series safety relays start at$198.

The BG5933 and BH5933 Seriesrelays offer protection for applicationswith two-hand buttons or productionmachinery with dangerous closingmovements. Available with 24VAC/DC, 110 VAC, and 230 VAC coilvoltages, the Category 4-rated relays areequipped with internal positive temper-ature coefficient resistor short circuitand voltage-dependent resistor overvoltage protection. These safetyrelays provide inputs for two pushbuttons, each with one normally-open and one normally-closed positiveguided contact. Output configurationoptions include either two normally-open positive guided safety contacts and

one normally-closed monitoring contact, or three normally-open positiveguided safety contacts and one normally-closed monitoring contact.Prices for BG5933 and BH5933 seriessafety relays start at $139.

Category-4 rated light curtain controllers have also been added.Designed for light curtains with symmetric or asymmetric outputs, theLG5925 24 VDC light curtain controller features three normally-openpositive guided safety contacts and onenormally-closed monitoring contact andprovides single or two-channel opera-tion. The LG5925 light curtain controller is priced at $115. A multi-function features two normally-openpositive guided safety contacts and onenormally-closed monitoring contact;the controller can connect up to threelight curtains, and offers protection,muting, and stepping modes. Themulti-function light curtain controller ispriced at $339.

The LG5929 extension moduleprovides additional contacts for emergency-stop modules and safety gatemonitors. Designed for one-channel ortwo-channel connection, the Category-4 rated extension module features fivenormally-open positive guided safetycontacts and one normally-closed monitoring contact. The LG5929extension module is priced at $95.

See the full line of Dold safety relayproducts at:www.automationdirect.com/safety-relays

What’s New

A

Product Description AutomationDirectPrice/Part Number

JUST A FEW PRICES ON SAFETY DEVICES

AutomationDirect prices are U.S. published prices as of March 2011.

Prices subject to change without notice.

Safety light curtain with 30mm resolution -24VDC, sender and receiver pair(sold separately) 0.25 to 12 meter operatingdistance, 279mm protective height,safety category 4

Safety limit switch, pull-reset action, plungeractuator, 30mm plastic body, 1/2 NPT

Safety relay module, single channel, for E-stop circuits, 24 VDC, 2 N.O. contacts

$250.00YBB-30S4-0250-G012 (sender)

$12.75AP2R11X11

$88.00LG5924-02-61-24

$275.00YBB-30R4-0250-G012 (receiver)

www.automationdirect.com/safety


1-800-633-0405


It could cost you a lot more in the long run. But you don’t need to overpay to get reliable, high-performance safetydevices that conform to all the latest standards. Our prices on safety relays, switches and light curtains mean you can doeven more to protect what’s important.

Safety relays protect people and machines.• Single and dual channel safety relays for E-stop and safety

gate applications• Two-hand Control units for positive protection• Light curtain controller modules are used in conjunction with

light curtains for monitoring/control

Safety switches with key or hinge interlocks, limitswitches and cable pull switches give precise,quick action.• Visible operation• Immunity to electromagnetic disturbances• Electrically separated contacts with positive opening

operation on N.C. contacts• Actuation speeds of 0.5 m/s (max) to 0.01 m/s (minimum)• IEC 947-5-1, EN 60947-5-1, UL 508, CSA C22.2 No 14 approvals

Safety light curtains in finger (14mm) orhand (30mm) protection resolutions• Protective height: 14mm resolution - 142 to 1045mm

30mm resolution - 279 to 1827mm• Operating distance: 14mm resolution - up to 3.5 mches

30mm resolution - up to 12 mches• Double PNP outputs• M12 quick-disconnect models (order cable separately)• IP65 rated; Type 4 and Category 4 PL e

Don’t let price stand in the way of makinga machine or process as safe as possible

Our shipping policies make it easier than ever to order direct from the U.S.!Free standard shipping is available for orders totaling over $300 U.S. (except for orders which require LTL shipping,see Web site for details). Also, save on brokerage fees when shipping standard ground to Canada - you can chooseto allow AutomationDirect to nominate a broker for your shipment for parts shipping via standard ground. Thiscan save you big on brokerage fees. See Web site for details and restrictions -


Product Snapshots

6

AutomationDirect renewspartnership with Kepwarefor communications

Kepware Technologies, the leaderin Communications for Automation,has renewed its contract asAutomationDirect's communicationssupplier. AutomationDirect will delivera single branded version ofKEPServerEX called "KEPDirect OPCServer" for use with AutomationDirectcontrollers and remote I/O.

KEPDirect OPC Server connectsyour preferred Windows client softwareby providing a flexible and scalable com-munications and OPC server solutionfor connecting, managing, monitoring,and controlling AutomationDirectEthernet remote I/O, DirectLOGICPLCs, and Productivity3000 PACs.Communications is managed through arobust platform that supports an arrayof open standards, proprietary commu-nication protocols, API’s, and variousautomation system interfaces.KEPDirect OPC Server ($399) enablesimproved operations and decision mak-ing throughout all levels of an organiza-tion.

As a "Connected with Kepware"company, AutomationDirect will workwith Kepware to ensure that the bestcommunication support is developedfor AutomationDirect products.“AutomationDirect has been an excep-

tional partner of Kepware for manyyears," said Tony Paine, President ofKepware Technologies. "We are not onlyextremely excited to renew our partner-ship, but also to expand on it by deliver-ing additional connectivity to their newProductivity3000 PAC.”

The companies will work togetherto support their joint customers throughthe partnership. Kepware will developdrivers for use on Windows™ desktopoperating systems (Workstation andServer). The KEPDirect OPC Serverwill be available throughAutomationDirect’s website and theirchannel partners.

"The Kepware relationship is veryimportant for us, as factory floor toboardroom data flow has become anintegral part of manufacturing systems,"said Jeff Payne, Product Manager forPLC, I/O, and PC Control ofAutomationDirect. "The support forour Productivity3000 PAC is key forapplications that can take advantage ofits robust communications platform.”About Kepware Technologies

Kepware Technologies develops awide range of communication and inter-operability software solutions for theAutomation industry. Our solutionsallow you to connect disparate softwareand hardware systems, providing appli-cations with quality, ease of use, andhigh performance. Furthermore, our in-depth experience with software design,development, support, and maintenanceallows us to provide high-performancecommunications software without sacri-ficing quality and ease of use.

Learn more about KEPDirect OPCServer at:www.automationdirect.com/kepdirect

Encapsulated transformersline expanded

The Hammond line of HPSFortress commercial encapsulated singlephase power transformers has beenexpanded to offer two new input voltagegroups and to increase our existing voltage group up to 25kVA. The newvoltage input groups include

277/240/208/120 VAC and220/208/200/190x440/416/400/380VAC. These new models allow for abroader range of input voltages and stillmaintain the 120x240 VAC output. Allunits are encapsulated with electricalgrade silica sand and resin compoundsto protect the core and coils, sealing outmoisture and airborne contaminantsand eliminating corrosion and deterio-ration. The NEMA 3R enclosures meetor exceed NEMA and ANSI standardsfor indoor and outdoor applications,and are UL and CSA listed as well as CEapproved. The Fortress series encapsu-lated power transformers are backedwith a 10-year limited warranty. Pricesstart at $77. To see the full line of HPS Fortress com-mercial encapsulated power transform-ers, visit:http://www.automationdirect.com/power-transformers

Inductive DC proximity sensors

The PEW series of stainless steelDC proximity sensors are flush-mount-able shielded 8mm sensors with a 2mmsensing range. Available with either M8or M12 quick disconnects, they areequipped with LED status indicatorsvisible at wide angles, and have PNPoutputs. PEW series inductive proximi-ty sensors are priced at $45.Also added are the LF40 series rectangu-lar inductive DC proximity sensors.Two shielded and two unshielded mod-els are available with 20mm or 35mmsensing ranges. The rectangular plastic

Press Releases

7



PNP sensors provide either normally-open or normally-open/normally-closedcomplementary outputs. LF40 seriessensor prices start at $39.

To see the complete line of proxim-ity sensors, visit :www.automationdirect.com/proximity

Compact fusible switchesavailable

GladiatorTM compact fusibleswitches have been added to our line ofcircuit protection devices. The single-pole, two-pole and triple-pole ACdevices are available in Class CC andMidget fuse models; single-phase DCdevices are also available. The 35mmDIN rail mountable switches’ compactsize takes up only one-third the space ofa molded circuit breaker and two-thirdsthe space of traditional fusible switches,saving space in control panels. The full

voltage rating of up to 600 VAC (80VDC) allows installation flexibility inmany applications where feeder andbranch circuit protection are required.

Equipped with lockout/tagoutcapability and finger safe construction,

Gladiator switches promote safe work-place practices by preventing contactwith live components. Open fuse indi-cation provides faster troubleshootingand reduced downtime.

Starting at $18, Class CC fusemodels are UL98 listed and have a200kA Short-Circuit Current Rating;Midget Class fuse models are UL 508listed and have a 10kA Short-CircuitCurrent Rating. A 5A auxiliary contactwith one normally-open and one nor-mally-closed contact is also available for$9.

View the full line at:www.automationdirect.com/disconnect-switches

Current sensing line expandswith ground fault sensorsand DC current transducersand switches

The acuAMP® line of current sensors now includes AC ground faultsensors and DC current transducers andswitches.

The GFS series of ground fault sen-sors monitors all current-carrying con-ductors in grounded single and three-phase delta or wye systems. Available infixed-core models, the GFS series fea-tures jumper-selectable setpoints of 5,10 or 30 mA. The sensors can accom-modate up to 14 AWG copper wire andfeature mechanical relay outputs witheither manual or auto reset. The UL andCE approved GFS series of ground faultsensors start at $136.

The DCT series of DC currenttransducers combines a Hall Effect sensor and signal conditioner into a single package for use in DC currentapplications up to 400A. Designed to becompatible with most PLCs, data loggers and SCADA systems, the DCTseries features jumper-selectable currentinput ranges and industry standard 4-20mA or +/- 10 VDC outputs. Available insplit-core or fixed-core models, DCTcurrent transducer prices start at $117.DCS100 series DC current switches feature jumper-selectable current inputranges up to 100A and are available innormally-open solid-state and SPDT

relay output models. The switches areequipped with removable terminalblocks which accept up to 12 AWGsolid or stranded wire. Prices forDCS100 DC current switches start at$90.

All acuAMP sensors are panel-mountable; convenient DIN rail adaptor accessories are also available.

The complete acuAMP series offersoutstanding features, flexibility, anddurability. Backed with a five-year warranty, the complete line of currenttransducers and switches providesdependable service for virtually anyapplication.

See the full line of acuAMP currentsensing products at:www.automationdirect.com/current-sensors

Photoelectric sensor lineexpanded

AutomationDirect’s photoelectricsensor offering now includes 18mm rec-tangular plastic DC models. The IP67rated sensors, available in 12 models, fea-ture an 18mm diameter threaded lens andM12 quick-disconnect.

The GX3 series is a diffuse photoelec-tric available with either NPN or PNPlight-on outputs and features backgroundsuppression technology with fixed sensingdistances of 100 mm or 150 mm. GX3series prices start at $49.

The GXP series is a polarized reflec-tive photoelectric available with eitherPNP light-on output or NPN or PNPdark-on output and feature fixed sensingdistances of up to 20 meters. GXP sensorsinclude one round reflector. GXP series

Continued, p. 9>>

Buy direct and save!Just about every electrical installation

needs a transformer, so we carry high-quality

Hammond Power Solutions products at great prices,

in stock and ready for shipping the same day.

Encapsulated Transformers

The Fortress series of encapsulated transformers aresingle phase units, now available in 100VA up to25kVA ratings.

The NEMA 3R enclosure makes them ideal for indoorand outdoor applications, such as schools, sportscomplexes, office buildings and lighting.

• 100VA to 25kVA sizes

• Input voltage ranges from 120 to 480 VAC

• Output voltages of 240 and 120 VAC

• NEMA 3R enclosure

• 10-year warranty

Control transformerswith lifetime warranty

HPS Imperator control transformers are specificallydesigned for high inrush applications requiring reli-able output voltage stability. New models expand theinput and output voltage ranges available, all at lowdirect prices!

• MGJ Control Series: 50VA to 500VA,380x277x208 primary, 240x120 secondary

• MLI Control Series: 50VA to 500VA,480x240 primary, 120x25 secondary

• MQMJ Control Series: 50 VA to 1.5kVA, 230x460primary, 115x230 secondary

• PG Control Series: 50VA to 1kVA, 120x240primary, 24x12 secondary

www.automationdirect.com/power


1-800-633-0405



9www.automationnotebook.com

prices start at $39. The GXR/E series are through-beam

photoelectric models available with eitherNPN or PNP light-on or dark-on outputsand offer fixed sensing distances of up tofour meters. GXR series receiver pricesstart at $35. GXE receiver-dependentemitters are available for $30.

65mm mushroom headmetal pushbuttons nowavailable

Fuji Command 30mm metal push-buttons with 65mm mushroom-styleoperators are momentary non-illuminatedpushbuttons available in four colors andcome with either a single normally-opencontact block (red available as normally-closed) or with one normally-open and onenormally-closed contact block.

Replacement contact blocks are available in single packs. UL listed andCSA certified, prices start at $19. See theFuji Command 30mm pushbuttons at:www.automationdirect.com/pushbuttons

Product Snapshots Cont.Press Releases

Continued from, p. 7

250-600 VAC rated current limitingEdison Fuses replace more expensivecompetitors’ fuses

• Class CC for lighting and heating loads, small motor circuits

• Class J for inductive loads, includingmotor and motor branch circuits

• Class RK for AC power distribution, lighting

www.automationdirect.com/fuses

Ferraz Shawmut 600 VAC/250 VDCheavy-duty fusible and non-fusibledisconnects meet UL98 standards,and are UL, CSA, CE and IEC rated.

• SIRCO non-fusible disconnect switches up to 800 amp ratings

• FUSERBLOC fusible disconnects break up to 200 amps; use with class CC or J fuses

• Accessories include handles and shafts, terminal lugs and shrouds, auxiliary contacts

www.automationdirect.com/disconnects

www.automationdirect.com/mccb

Molded Case Circuit Breakers forbranch and feeder circuit protection

• From 15 to 800 amps• High-speed “blow-open” action• Small size saves panel space• UL489 listing

“The government's view of theeconomy could be summed up in afew short phrases: If it moves, tax it. Ifit keeps moving, regulate it. And if itstops moving, subsidize it.”

– Ronald Reagan (1911–2004)

“A committee is a cul-de-sac downwhich ideas are lured and then quietlystrangled.”

– Sir Barnett Cocks (1907–1989)

“What's another word for Thesaurus?”

– Steven Wright

Feature Story

10

Trends in Automation

Upgrading PumpStations with PLCs:When relays andtimer circuits get old,they cause problems.Replacing them withPLCs keeps pumpsrunning smoothly. By Henry PalechekProcess Control Supervisor

ne of the most importantjobs of a water distributionsystem is to reliably deliver

water to its customers. At our water district in California, we had pumpingstations (Figure 1) with relay-based controls that were more than 30 yearsold, and the vintage of the controlscaused a definite reliability issue.

A typical pump station has three orfour pumps, each powered by 100 or125 horsepower motors. Because of therelatively large motor size, a part winding motor starting system is used

with two motor starters. When thepump is turned on, the first motorstarter is energized. Then, after a timedelay, the second starter is energized.

Two types of timers were used inthe control logic, pneumatic and electronic. As the pneumatic timersaged, they lost their timing repeatability.It was common to hear the motor strainwhile waiting for the second starter topull in.

Electronic timers were sometimeseven worse as their electrolytic capacitors failed over time. When thetimers failed it was hard on the motorbecause it was running on only one

starter until the overload tripped.Personally, I’ve had to replace more ofthe electronic timing relays than anyother device in the control circuit. Ithought it was time to upgrade thepump controls and my company agreed,so we decided to investigate alternatives.Taking a Test Drive

We decided to do a pilot test ontwo stations over a one-year period. Wereplaced all the pneumatic and electricalrelays with DL05 PLCs fromAutomationDirect (Figure 2). ThePLCs were installed inside the motorcontrol center (MCC) buckets by ourin-house district electricians.

When the first pilot pump controlcircuit was changed over to PLC control, I set the delay time between theactivation of the two motor starters to

O

Figure 1: Typical pumping station in the water distribution system.

FIgure 2, Before replacement

Figure 2: Before and after. The original relay-based system (above) was cluttered, while the updated PLC-based controls are much cleaner.

0.5 seconds. Our control electrician didn’t like the way the motor sounded,so with one quick edit I set the timer to0.4 seconds. We’ve never had to readjustthem since, and there’s no longer anydrift in the timing because the PLC is adigital device.

We were concerned about how wella PLC would hold up in the hot andelectrically noisy environment of anMCC without cooling or a UPS, butthey have proven to be very robust. Theonly failure we had was when a pumpcontrol valve’s solenoid shorted out andpulled an excessive amount of current.Installing a fuse on the output solvedthe problem. It should be noted that thisfailure was our fault as we should haveinstalled an output fuse in the firstplace.

We’ve since installed about 55DL05 PLCs in our pumping stations,one on each motor, with no reliabilityissues in more than a decade of service.

Another advantage is the PLC simplifies and enhances pump opera-tion. A typical MCC had hundreds ofwires and dozens of relays (Figure 3) inmultiple buckets. In some cases the wirenumbers had fallen off over time, whichmade troubleshooting very difficult. Inaddition, the control logic only provided one alarm pump timeout.When a pump failed to start properly,we were never sure why it had failed.

The specific problem was thatwhen a pump failed to operate properly,it would time out and couldn’t berestarted until manually reset by anoperator. This reset cleared the timeoutrelay logic, making it hard for the tech-nician to troubleshoot the problem.

Now, the PLC is programmed so thealarm can be reset by the operator; thisallows the pump to run, while main-taining failure information in the ladderlogic until the relevant area of the PLCprogram is reset by the technician. Thisgave us better flexibility in that a failedpump can be returned to service with-out losing information vital to the trou-bleshooting process.

Another enhancement was toexpand the type of alarms sent back tothe central SCADA system. Now, thealarm is defined three different ways:pump fail, MCC fail, or pump controlvalve fail. Before the upgrade, it wascommon to have a few pumps fail tostart every week, but that’s no longer thecase. Dealing with water hammer

In a water distribution system,another area of concern is always waterhammer. Water hammer occurs whenwater flow is halted abruptly, causing ashock wave to travel through the line.The force of the shock wave can causesevere damage to critical control parts.When a large pump is started in ourwater pumping application, a pumpcontrol valve is used on the output ofthe pump to stop the possibility of awater hammer (Figure 4).

The motor is started into a closedpump control valve, and the valve isallowed to open slowly. On shutdown,the valve is closed slowly and a micro-switch notifies the controller to turn offthe motor.

Here’s the sequence of events thatoccur when a large pump is started:

1. The first motor starter pulls in2. The second motor starter

pulls in3. The pump control valve is

commanded to open4. The pump control valve is

monitored to ensure it fully opens

Every step is timed, and if there’sany failure of the proper sequence themotor is automatically turned off. Thepump is then held out of service until anoperator investigates the problem andpushes a reset button.

The old system was a nightmare totroubleshoot with its pneumatic andelectrical relays. Now, with the PLC,finding the source of the problem ismuch easier.

The PLCs have allowed us to solveour control issues at a low cost with high



Figure 3: The pile of parts left over when a PLCreplaced relays in an MCC.

Figure 4: A pump control valve prevents water hammer by opening and closing according to a careful timing sequence.

Continued, p. 13>>

The DL205 micromodular PLC is an industry workhorse,time-tested in some of the toughest industrial settings.Installed in thousands of applications, its wide range of I/Oand communication options ensure you’ve got the tools youneed to do the job. And our direct prices, 30-day money-back guarantee and FREE award-winning technical supportare all standard features that make that job a little easier!

DISCRETE: Choose from 25 discrete modules thatsupport AC, DC and relay I/O types. All moduleshave removable terminal blocks for easy wiring andmodule replacement. Our newest DC outputmodule performs electronic short circuit protection.

ANALOG: 19 analog modules offer interfaces tocurrent and voltage signals, as well as thermocouplesand RTDs. Connect devices such as process transmitters,proportional valves and AC drives.

COMMUNICATIONS: The DL205 series makes Ethernetcommunications easy and inexpensive. Get fastpeer-to-peer access to HMI, other PLCs and PCs on thefactory floor at one of the lowest costs per node in theindustry.

Test-drive the software for FREE! Our fully functional PC-DS100 programmingpackage can create and download programs to all our DirectLOGIC PLCs(max 100 words runtime; unlimited programming package PC-DSOFT5 is $395 ).Download the software online at:

DirectLOGICDL205

Allen-BradleyCompactLogixPLC modules

* All prices are U.S. published prices. Prices and specifications may vary by dealer and configuration. AutomationDirect pricesare from March 2011 Price List. Allen-Bradley prices are based on www.rockwellautomation.com/en/e-tools 3/7/11.

Discrete ModulesAC 16-pt. inputDC 16-pt. input

DC 16-pt. outputIsol. relay 8-pt. out

Analog Modules4-channel input (current)

4-channel thermocouple in8-channel output (voltage)

CommunicationsEthernet interface

$277$236$308$284

$476$967 (6-ch)$1,430

$783

$128$86$94$99

$199$299$269

$299

CHECK OUT OUR PRICES ON PLC MODULES


1-800-633-0405


www.automationdirect.com/plcs

HIGH-SPEED/MOTION: Counter modules include asimple counting input module or a high-speedinput/pulse output module for interfacing to stepper orservo drives. Using our SureServo or SureStep motionsystems with the DL205 gives you a very cost-effectivemotion control system.

High-speedcounting

http://support.automationdirect.com/downloads.html


Feature Story Cont.Trends in Automation

reliability. We still use the brick styleDirectLOGIC DL05 PLC in existingMCCs, but in our new MCCs we’veupgraded to the DL06 PLC, which hasmore expandability and a local LCDdisplay option. We expect similar reliability from the DL06 PLCs, alongwith continued ease of use and superior vendor support.


About the Author

Henry Palechek is the informa-tion systems and process controlsupervisor at a water utility inCalifornia. He’s been with the utilityfor over 16 years. He holds aBachelor of Science in InformationSystems, and has been teaching watertechnology courses at the local com-munity college since the mid 90s. Healso holds a California T3 Operatorlicense.


www.automationdirect.com/wire_duct

www.automationdirect.com/enclosures

www.automationdirect.com/cable-ties

Rigid and flexible wire duct &Liquid-tight tubing

Solid duct now available

• All rigid duct comes in 2 meter lengths, withcover, sold individually or in value packs

• Open slot duct now available in blue andblack, as well as gray and white

• 30-meter liquid-tight tubing, coils in diametersfrom 3/8 to 2 inches

Over 1,600 enclosures fromHubbell/Wiegmann

• NEMA 1, 3S, 3R, 4, 4X, 6P, 4/12 and 13 metallicenclosures

• Non-metallic line for harsh outdoorenvironments in NEMA 3R or 4X

• Steel and stainless flanged enclosures fordisconnect mounting

Wire ties and accessories sold in 100 or 1,000piece packs, starting at only $1

• Standard ties in white and black in 4 to32-inch lengths

• Black nylon lashing ties in 9 to 40-inch lengths• Releasable ties in 6 to 12-inch lengths• Mounting head ties available in 4 to 12-inch

lengths• UV-resistant ties in 7 to 14-inch lengths• Identification cable ties available from 4 to 12

inches long

“Arithmetic is being able to count upto twenty without taking off yourshoes.”

– Mickey Mouse (1928–)

Complete PLC starting at $69Mighty as a stand-alone unit,or expand to 142 total I/O

Product Description AutomationDirectCLICK

Price/Part Number

CHECK OUT JUST A FEW PRICES ON CLICK

AutomationDirect prices are U.S. published prices as of March 2011. Prices subject to change without notice.

PLC CPU with 8 DC inputs / 6 DC outputs(sinking), two communication ports

Auxiliary power supply (0.5A), 100-240 VAC input,24 VDC 0.5A output

AC input module, eight 100-120 VAC points

$69.00C0-00DD1-D

$29.00C0-00AC

$40.00C0-08NA

PLC CPU with 4 DC inputs / 4 DC outputs(sinking), 2 analog inputs / 2 analog outputs,three communication ports, real-time clock

$129.00C0-02DD1-D

With CLICK PLCs, you get a lot of application control in asmall package. The new Standard CPUs feature thediscrete I/O configurations of the Basic CPUs, plusbattery-backed memory, real-time clock and a thirdcommunication port. Download the free programmingsoftware now and see how easy automation can be.

• Eleven stand-alone DIN-rail mountable DC-powered CPUcombinations including:- 8 DC In / 6 DC Out (sinking) -Basic and Standard- 8 DC In / 6 DC Out (sourcing) - Basic and Standard- 8 DC In / 6 Relay Out -Basic and Standard- 8 AC In / 6 Relay Out -Basic and Standard- 4 DC In / 4 DC Out (sinking), 2 analog in, 2 analog out

(current / voltage selectable)- 4 DC In / 4 DC Out (sourcing), 2 analog in, 2 analog out

(current / voltage selectable)- 4 DC In / 4 Relay Out, 2 analog in, 2 analog out

(current / voltage selectable)

• Built-in communication ports(two in Basic CPUs, three in Standard and Analog CPUs)

• Battery-backed memory and real-time clock(in Standard and Analog CPUs)

• Removable terminal blocks for easy wiring• Eleven stackable, discrete I/O option modules• Program AND documentation stored in CPU• Supported by FREE, high-feature programming software www.automationdirect.com

1-800-633-0405


New Standard CPUs start at $99

http://www.automationdirect.com/click-plc or www.clickplc.com


System Integrator CornerUL 508A Certified Panel ShopsBy Tim Roberts,AutomationDirect

everal member integrators inAutomationDirect’s SIDirectprogram have UL 508A certified

panel shops. Although many installa-tions and applications do not specifyadherence to the UL 508A standard, it’sgood to be aware of the benefits of ULlisting for your control panels.

The UL listing mark on an indus-trial control panel provides evidence ofthird party certification. It indicates thatthe panel complies with an accepted andspecific safety standard. The listingmark may be applied to a wide variety ofdesigns – from custom built to stan-dardized designs with minor modifica-tions.

While there is a confusing array ofelectrical safety standards to contendwith, from the overarching nationalelectrical code (NEC) to specific areasaffecting control panels, such as NECArticle 409, the most commonly refer-enced standard for industrial automa-tion applications is UL 508A. Brieflystated, UL 508A is the standard forSafety of Industrial Control Panels. Therequirements specified in UL 508A arein turn based on UL 508, the standardfor Safety of Industrial ControlEquipment, the NEC, NFPA 70 andthe standard for industrial machinery,NFPA 79. One important service a cer-tified UL 508A panel shop offers is toapply these standards to customer appli-cations and designs.

Out of the 38 system integrationfirms in the USA that are members ofAutomationDirect’s SIDirect Program,the following ten are UL 508A certifiedPanel Shops.

Please contact them to find outhow they can meet your UL 508A panelrequirements.

ADVANCED PROCESS SOLUTIONSMILWAUKIE, OR 97267Contact: Bill PascoePhone: 971-506-9338Web site: www.YourAPS.com

HEYWOOD ENGINEERING, INCRENO, NV 89511Contact: Lance HeywoodWeb site:www.heywoodengineering.com

ICADFresno, CA 93725Contact: Cliff TaylorWeb site: www.icadautomation.com

ROBEY CONTROLSRaymond, ME 04071Contact: Timothy RobeyWeb site: www.robeycontrols.com

AI CONTROL SYSTEMSReading, PA 19605Contact: SalesWeb site: www.aicontrols.com

INDUSTRIAL AUTOMATIONLa Crosse, WI 54602Contact: Herb BurfieldWeb site:www.industrialautomation.us

ONEIL ELECTRIC COGreeley, CO 80631Contact: Greg O’NeilWeb site: www.oneilelectric.net

PACIFIC COAST AUTOMATION, INCModesto, CA 95356Contact: John KellerWeb Site: www.pca-inc.com

S&L AUTOMATION, INCLenoir, NC 28645Contract: Lori PlessWeb site: www.sandlautomation.com

ENER TECH ASSOCIATES, INCHarrisburg, PA 17112Contact: Sam MorelloWeb site: www.eta-inc.com


S

“If there's anything unsettling to the stomach, it's watching actors on television talk about their personal lives.”

– Marlon Brando (1924–2004)

House Theatre of ChicagoBy Ryan Poethke

ouse Theatre of Chicago’soriginal-script production ofThe Nutcracker demanded

moving, changing scenery that magically transformed the set at thepush of a button. AutomationDirect’sextensive line of pneumatic and electrical components helped us realizethese design elements easily, elegantly,and reliably.

The doors:The set design consisted of five sets

of custom built French door units whichwere completely freestanding. Thesedoor units provided the “theatre-in-the-round” entrances for the actors. At theclimax of the show, when young Clara’sworld is about to fall apart, scenicdesigner Collette Pollard envisioned the

world physically cracking and beginningto come apart.

Using AutomationDirect’s single-acting pneumatic cylinders, the “doortoppers,” situated above the doors, piv-oted from one side, pushed up by thecylinder.

The cylinders were embedded inthe vertical doorframe posts. The frameswere constructed of 2” square steel boxtube to provide a hollow space for thecylinders, and then cased in wood toprovide the proper dimensions andappearance.

To prevent binding, the cylinderwas topped with a plastic ball whichallowed the end to slide as the cylinderextended. The air line ran down theframe and out to the control panelupstage.The tree:

The closing scene of Nutcrackercalled for a small Christmas tree to magically grow from the stage on command. The design team wanted a

16

User SolutionsCreative Control Solution

H

17



tree that grew from nothing to approxi-mately 18 inches. The tree planter, filledwith fake snow, had a false bottomwhich the tree punched through tomagically appear when desired. Our“Charlie Brown Tree” was built fromvarious diameters of polyethylene tub-ing wrapped with soft iron wire andcovered with painted heatshrink tubing.The hinges at the base of the brancheswere simply short lengths of extensionspring which allowed the tree to collapseinto a piece of 1.5” PVC pipe.

The tree was pushed up throughthe floor by a 1” bore, 18” stroke double-acting cylinder. The double-acting feature allowed the stage crew toeasily retract and reset the tree betweenperformances.

The cylinder was able to push thetree around the 90-degree bend becausethe tree’s “trunk” was also made of polytubing; flexible yet rigid enough towithstand pushing by the cylinder.

There are three air lines attached tothe under-stage tree mechanism; oneeach to extend and retract, as well as apurge line that was used to blow the

fake snow out of the tree storage tubebefore retraction. The purge line wasadded after we found that the fake plas-tic snow which fell into the tube pre-

vented the tree from moving smoothly.It is important to note that the tree itselfremained vertical and never “turned thecorner.” The horizontal portion con-tained only the travel of the cylinderand the poly tubing “pushrod.”

The control panel:The AutomationDirect three-way

pneumatic valves were operated by aneight-way MIDI-to-relay card throughsingle-pole interposing relays. MIDIcontrol was chosen as it is a control pro-tocol native to the audio world; sincethe effects had to fire in time with soundeffects, it made sense to allow the audioplayback computer to control the actua-tion of the valves.

It might be noticed that eventhough we have a double-acting cylin-der for the tree, all eight valves are 3-way, and not necessarily suited to con-trolling a double-acting cylinder. Wesimply used two 3-way valves, one foreach side of the cylinder, to minimize airloss around the seals of the cylinders.Because we could not run our compres-sor during the show due to noise, our airsupply was limited. Use of the single-acting cylinders was limited to a rathershort time, and the tree’s cylinder didnot need air once it was extended or

retracted. The purge line used to blowthe fake snow out from around the treewas only used post-show, and thus wewere able to run the compressor as need-ed for additional air.

A large white cylinder was mount-ed to the left of the panel to serve as amuffler; it silenced the sound of ventingair as the cylinders were extended andretracted. It was built from 3” diameterPVC pipe and fuzzy paint rollers withtheir center tubes glued closed. Thisforced the air through the nap of therollers and out through a grate on thebottom of the pipe.

Our use of AutomationDirect’sextensive line of pneumatic and electricsupplies and parts allowed HouseTheatre to tell the tale of TheNutcracker in ways that truly broughtthe audience into the story. Withoutsupport from AutomationDirect, HouseTheatre would not have been able toadd this dimension of scenery move-ment and magic to our storytelling.

Tech Thread

18

PLC-based systemworks where singleloop temperature controllers fell shortBy Tim Hanes,AutomationDirectProcess Instrumentation Equipment Product Engineer

n many applications, single looptemperature controllers are sufficient to provide control of

heating and cooling. But in some applications, including the one detailedin this article, closely coordinated control among many temperature control loops is needed. In those casesand others, PLC-based temperaturecontrol can be the best solution.

A meltblown machine, a meltedpolymer extrusion machine used inmanufacturing nonwoven materials,consists of four main components. Anextrusion system provides a steady supply of molten polymer, and a heated

spinbeam distributes the polymer intoan even sheet or web. A heated processair system is used to attenuate or stretchthe fibers, and a vacuum system removesthe process air as the nonwoven web is formed.

The spinbeam consists of a large304 stainless steel die body block weigh-

ing approximately 8 tons, and heated by72 1.1 kW electric cartridge heaters.The heaters are paired into 36 zonesspaced on 4” intervals down the lengthof the block.

On this machine, each of the 36 zones had a PT100 RTD temperature sensor for feedback to thatzone’s single loop temperature controller. An output from each controller switched a pair of cartridgeheaters to maintain an average blocktemperature around 425°F. Biasing setpoints for each of the 36 individualzone temperature controllers could beentered by the operators of the machineto adjust the temperature profile acrossthe length of the spinbeam.

Process air heated by a 320 kW electric circulation heater is delivered bya low pressure blower through large airmanifold assemblies. These assembliesare constructed of 0.75” thick 304 stain-less steel plate attached to the die bodyusing 28 12mm grade-8 bolts.Varying Rates of Thermal Expansion

Thermal expansion of metal as it isheated is normally not a problem if allassembled parts expand at the same rate,or if clearances with tolerances down tothe thousandths of an inch aren’trequired. But in this case, there were

Temperature Control

I

Figure 1, Machine diagram.

Figure 2, Example of Meltblown Die Assembly


significantly different rates of thermalexpansion for the die body and the airmanifold. This was causing these twocomponents to separate to the extentthat the bolts connecting the assemblieswere shearing.

When the meltblown machine wasstarted, the solid die body was heatedwith the cartridge heaters at a rate of 2°per minute. The air manifold assemblieswere heated only by the pre-heatedprocess air, and were thus increasing intemperature at a rate of about 1° perminute. With the two different heatingrates, it didn’t take long to develop a significant temperature differentialbetween the die body and the air manifold assemblies.

Because the solid stainless steel diebody was more efficient at conductingheat than the hollow air manifolds, itcould expand in length by as much as1% (or 1.4 inches) before the air manifolds could expand. Something hadto give, and in this case it was often oneor more of the 28 bolts attaching the airmanifold assemblies to the sides of the spinbeam.

The workaround solution was continuous intervention from themachine operators to monitor the diebody and air manifold temperatures,and to adjust the temperature setpointson the 36 individual controllers as

required. A better solution was needed,one that replaced constant operatorattention with automated control. The Power of the PLC

After analysis and process trials, it was determined that the system could handle a maximum temperature differential of about 50°F between thedie body and the air manifolds withoutshearing the bolts.

One possible solution to maintain amaximum temperature differential wasto install heaters and additional controlson the air manifold assemblies.

However, due to their complex shapeand space limitations, this solution wascost prohibitive.

A better solution was an improvedautomation system in the form of a PLCand a Human Machine Interface(HMI). Historically, PLCs were used fordiscrete control applications, but today’spowerful PLCs have greatly expandedcapabilities, particularly in the area ofanalog monitoring and closed loop control. These capabilities are providedin compact and low cost controllers featuring ease-of-use and a high degreeof connectivity.

On the meltblown machine, theindividual single loop controllers wereeliminated and the 36 RTD zone temperature sensors were wired to

individual analog inputs at the PLC.Also, temperature sensors were added tomonitor the incoming temperature ofthe pre-heated process air entering theair manifolds.

Using the PLC’s internal mathfunctions, the 36 die body zone temperatures are averaged and compared to the incoming air temperature in the air manifolds. Basedon the measured temperature differential, the PLC automatically


Figure 3, Example HMI Screen

Figure 4, Example Bicomponent Meltblown Machine

Continued, p. 21>>

* Software and firmware aredownloadable for authorizedcustomers from:www.automationdirect.com

www.automationdirect.com/c-moreREMOTE ACCESS AND CONTROL BUILT-IN

No Additional Hardware required. The C-more RemoteAccess feature resides in all panels with Ethernet support,and requires no option modules. Access real-time dataor initiate an action on a control system from anywhere,any time. (Requires software and firmware version 2.4 or later*, and anEthernet C-more panel)

C-more touch panels in 6" to 15" sizes are a practical wayto give plant personnel easy access to controls and data. Check out the powerful yet easy-to-use configurationsoftware by downloading a demo version at:

http://support.automationdirect.com/demos.html

ALL C-MORE PANELS INCLUDE:• Analog resistive touch screen with unlimited touch areas• One USB A-type and one USB B-type port• Serial communications interface

FULL-FEATURED MODELS ADD:• 10/100Base-T Ethernet communications• CompactFlash slot for data logging

C-more touchpanel line-up:

6-inch STNgrayscale

6-inch TFT65,538 colors

8-inch TFT10-inch TFT 12-inch TFT

15-inch TFT

Starting at:$399

Starting at:$499

$999 $1,595 $1,895 $2,295

CONNECT TO CONTROLLERS WITH DRIVERS FOR:• All AutomationDirect PLCs/PACs• Allen-Bradley

ControlLogix®CompactLogix®MicroLogix™ 1100/1400 Ethernet ENI Adapter for SLC Series FlexLogix SLC® 5/05 Ethernet™ MicroLogix™

• Modbus RTU and TCP/IP Ethernet • GE 90/30 SNPX (90/30, 90/70. Micro90, VersaMax Micro)• Omron Host Link Adapter (C200/C500), FINS Serial

and Ethernet • Selected Mitsubishi FX Series, Q Series • Siemens S7-200 PPI and S7-200/300 Ethernet

(ISO over TCP/IP)

C-more operator touch panels offer:

• Clear TFT 65K color displays(6-inch STN models also available)

• Analog touch screen for maximum flexibility

• Easy-to-use software


1-800-633-0405


®


ramps the setpoints of the die bodyzones to individually control each zone’spair of cartridge heaters. Specifically, thePLC determines the correct setpoint foreach of 36 PID control loops. Each loopreads an RTD input as the process variable, and uses the internally derivedsetpoint to modulate a control variableanalog output to control the heaters.

This PLC-based control solutionallows the machine to automaticallyheat at a rate that is compatible with thethermal expansion of the different components. The bolt shearing problemwas solved, and the need for constantoperator intervention was eliminated.

In addition, pre-programmedbiased setpoint temperature profiles inthe PLC can now be automatically usedas required, eliminating the need formachine operators to enter separatebiasing setpoints in the individual singleloop controllers.

In addition to the improved control functionality, the PLC continuously provides and trends valuable data to the HMI, such as theprocess variable, the setpoint includingany biasing, and the loop output controlvariable. Alarm points and conditions,either globally or for each loop, can alsobe viewed at the HMI. Touch screenHMI inputs allow changes dependingon different conditions such as the polymer type.

Prior to the use of PLC-based control, constant operator interventionwas required to provide safeguardsagainst damage and to manually trackvarious process conditions. By introduc-ing PLC-based control, possiblemachine damage due to varying rates ofthermal expansion has been eliminated,and valuable insight provided by tracking and trending data that wasn’t readily available from the single loop controllers.

For complex temperature controlapplications with different heating orcooling profiles, PLC-based controloffers a versatile, powerful and cost-effective solution. When paired with a

touch screen HMI, additional processdata can be viewed and analyzed, withadjustments to improve operations easily entered through the touch screen.

Tech Thread Cont.Temperature Control



“Money can't buy happiness, butneither can poverty.”

– Leo Rosten (1908–1997)

“Instant gratification takes too long.”

– Carrie Fisher (1956–)

“Success is liking yourself, liking whatyou do, and liking how you do it.”

– Maya Angelou (1928–)

Business Notes

22

By Joan Welty,Managing Editor

Kickstart and othernew videos

ave you seen the newestproducts launched byAutomationDirect? Now

you can watch short videos with productdescriptions, features and tips. Our new“KICKSTART” video program can befound on our Learn site and on ourYouTube channel. Check out these shorttwo-minute videos on products such asour new compact air cylinders, coiled airhoses, compact fuse switches and more.

Visit:http://learn.automationdirect.com andlook for the Kickstart tab along the top.

Or, go to:www.youtube.com/automationdirect,where you can subscribe to our YouTubechannel and leave comments on each video.

Other videos released recentlyinclude a four-part tutorial series whereproduct manager Jeff Payne shows youhow to use the many features of theProductivity3000 PAC programmingsoftware. Watch these under theSoftware tab on the Learn site.

Value Added Services

In keeping with our objective toprovide the best value in industrial control products, AutomationDirect’snew Value Add Services departmentprovides customers with cost savings bypackaging some of our high-quantitypackaged products into smaller pre-defined quantities. Product areaswhere this has been done include fuses,supplementary protectors, DIN rail,and flexible cord.

Other services include some pre-assembly and customization. Wecan pre-assemble Productivity3000 controller racks with I/O modules basedon your specifications. For a nominalcharge, this service can save you timeand effort, allowing you to completeprojects or machine assembly morequickly. For more information on thisassembly service, please visit theProductivity3000 Web site.(www.aboutplcs.com/p3000)

For OEMs, we offer a service toapply customer-supplied logo overlaysto our products, which gives the equipment a custom look. We’re continuing to find more ways to meetyour specific needs. If there is somethingwe could do for you, we welcome theopportunity to evaluate the idea.

Give us your 2 cents

Our newest online CustomerForum category is where you can tell uswhat you think. The Give Us Your 2Cents forum is the place to providefeedback and make requests on anythingfrom Web seminar topics to Web storefeatures to our company in general, youname it. You’ll have opportunities toparticipate in brief surveys, provideapplication story ideas and answer occasional questions. Go tohttp://forum.automationdirect.comand look for the “Give Us Your 2 Cents”Forum.

Get your WarrantyReturn number theeasy way - online!

We have tried to make our productreturn process one of the easiest andleast stressful you've experienced. As amatter of fact, we get "love letters" fromcustomers telling us how pleasant it wasto return a product to us! (We love tohear that, but we don't recommenddoing it just for the experience.) Butwhen you really do need to return aproduct that is under warranty, you cannow obtain the Return Authorization

H

Goings-on in the Industry

23



under your account via the Web. (Alldate codes and/or serial numbers mustbe supplied before the RA can beissued.) The process is this easy:

1. After you have logged in to your AutomationDirect account, visit our Returns page and choose the appropriate return reason.

2. You'll see a list of your orders which fall within the selected return window. Choose the order which contains the itemsyou wish to return.

3. Verify your contactinformation, view the list of items from your order, and enter the quantities you need to return. Then "Submit" the return.

4. The Returns Team will look over your return request, and if everything checks out, thenecessary paperwork andinstructions will be sent to youimmediately. (You can also obtain a 30-day money-back return authorization online.)

AutomationDirectsponsors VEXRobotics WorldChampionships

AutomationDirect was pleased tosponsor the recent VEX Robotics WorldChampionships at the ESPN WideWorld of Sports Complex (withinDisney World) near Orlando, FloridaApril 14-16. Over 500 teams comprised

of 3500 high school, middle school, andcollegiate students came together to celebrate their accomplishments andcompete with (and against) the best ofthe best. These were the top roboticsteams from over 200 VEX tournamentsthat took place around the world fromMay 2010 to March 2011.

Eleven teams from our local schoolsystem (Forsyth County, GA) qualifiedto attend, and one of those teams (fromNorth Forsyth High) made it to thesemifinal round! Congratulations to allthe teams who made it to Orlando.

After a series of intense back-to-back matches and elimination rounds,the High School Champion allianceemerged with teams comprised ofMassachusetts' Green Egg RoboticsClub, Washington's W.A.S.A.B.I. 2 andOntario, Canada's Simbotics teams.

The Middle School Champion represented an alliance of China teamsfrom Sichuan Chengdu Longjiang RoadPrimary School and the ShanghaiLuwan Teenagers Activity Center.

The College Championship titlewent to Massey University from NewZealand. In addition, one team fromeach of the three divisions was present-ed with an Excellence Award, the highest honor in the VEX RoboticsCompetition, given to the team withthe most well-rounded VEX Robotics

Program. Middle School, High Schooland College Excellence Award winnersincluded, the VEXMEN: NightCrawlerteam from Downingtown Area Roboticsin Downingtown, Pennsylvania, theCheesy Poofs from Bellarmine CollegePrep in San Jose, California, and MasseyUniversity in New Zealand.

Learn more about VEX:http://www.vexrobotics.com

Tech Brief

24

Top 10Tips: Specifying VFDs(Part one of a two-part series)By Joe Kimbrell,AutomationDirect Drives, Motors, and Motion Control Product Manager

ariable frequency drives — orVFDs — can reduce energyconsumption, improve real-

time control, and lengthen motor life;selecting the right one for your applica-tion requires asking the correct questions. Here are some expert tips toconsider. Determine if a VFD is right for yourapplication.

The primary function of a variablefrequency drive is to vary the speed of athree-phase ac induction motor. VFDsalso provide nonemergency start andstop control, acceleration and decelera-tion, and overload protection. In addition, VFDs can reduce the amountof motor startup inrush current byaccelerating the motor gradually. Forthese reasons, VFDs are suitable for conveyors, fans, and pumps that benefitfrom reduced and controlled motoroperating speed.

A VFD converts incoming acpower to dc, which is inverted back intothree-phase output power. Based onspeed setpoints, the VFD directly variesthe voltage and frequency of the invert-ed output power to control motorspeed. There is one caveat: Convertingac power to a dc bus — and then backto a simulated ac sine wave — can useup to 4% of the power that would bedirectly supplied to a motor if a VFD

were not used. For this reason, VFDsmay not be cost-effective for motors runat full speed in normal operation. Thatsaid, if a motor must output variablespeed part of the time, and full speedonly sometimes, a bypass contactor usedwith a VFD can maximize efficiency.Consider your reasons for choosing a VFD.

Typical reasons for consideringVFDs include energy savings, controlled starting current, adjustableoperating speed and torque, controlledstopping, and reverse operation. VFDscut energy consumption, especially withcentrifugal fan and pump loads.Halving fan speed with a VFD lowersthe required horsepower by a factor ofeight, as fan power is proportional tothe cube of fan speed. Depending onmotor size, the energy savings could payfor the cost of the VFD in less than two years.

Starting an ac motor across the linerequires starting current that can bemore than eight times the full load amps(FLA) of the motor. Depending onmotor size, this could place a significantdrain on the power distribution system,and the resulting voltage dip couldaffect sensitive equipment. Using aVFD can eliminate the voltage sag associated with motor starting, and cutmotor starting current to reduce utilitydemand charges.

Controlling starting current canalso extend motor life because across-the-line inrush current shortens life

expectancy of ac motors. Shortened lifecycles are particularly prominent inapplications that require frequent start-ing and stopping. VFDs substantiallyreduce starting current, which extendsmotor life, and minimizes the necessityof motor rewinds.

The ability to vary operating speedallows optimization of controlledprocesses. Many VFDs allow remotespeed adjustment using a potentiome-ter, keypad, programmable logic controller (PLC), or a process loop controller. VFDs can also limit appliedtorque to protect machinery and thefinal product from damage.

Controlled stopping minimizesproduct breakage or loss, as well asequipment wear and tear. Because theoutput phases can be switched electron-ically, VFDs also eliminate the need fora reversing starter.

Select the proper size for the load.When specifying VFD size and

power ratings, consider the operatingprofile of the load it will drive. Will theloading be constant or variable? Willthere be frequent starts and stops, or willoperation be continuous?

Consider both torque and peakcurrent. Obtain the highest peak current under the worst operating conditions. Check the motor Full LoadsAmps (FLA), which is located on themotor’s nameplate. Note that if a motorhas been rewound, its FLA may be higher than what’s indicated on thenameplate.

V

Continued, p. 28>>

Using VFDs to operate fans and pumps can significantly reduce energy consumption, becausethey can tailor fan speed to the application. Fan

horsepower is proportional to the cube of fanspeed, so depending on motor size, energy savingscan compensate for the initial VFD purchase price

in less than two years.

In addition to varying speeds, conveyor applicationstypically require frequent starting and stopping.

Here, VFDs substantially reduce starting current toextend motor life.

Variable Frequency Drives

CHECK OUT OUR PRICES ON MOTORS

AC, 208-230/460V,3-phase, TEFC,1800 rpm, 1 hp

AC, 208-230/460V,3-phase, TEFC,1800 rpm, 20 hp

PMDC, 56C,2 hp, 180V

$124.00MTR-001-3BD18

AutomationDirectIronHorse

Baldor

$522.00MTR-020-3BD18

$368.00MTPM-002-1M18

All prices are U.S. published prices. AutomationDirect prices are from March 2011 Price List. Baldor prices taken from www.baldor.com 3/7/11. Dayton prices taken from www.grainger.com 2/22/11.Emerson prices taken from www.usmotors.com 2/22/11 or www.mscdirect.com 2/22/11. Prices and specifications may vary by dealer and configuration. Prices subject to change without notice.

$419.00CM3546

$2,034.00M2334T

$2,347.00CDP3585

$253.254THX2

Dayton

$270.44U1E2D

$1,391.30U20E2D

$2,301.00G644 (1.5 hp, not 56C)

Emerson

$1,261.004Z380 (not 56C)

www.automationdirect.com/motors

Heavy-duty DC motorsIRONHORSE PMDC motors areavailable in TENV and TEFC enclosurestyles. Space-saving designs featurea NEMA 56C flange and removablemounting base.

• Rolled steel frame/cast aluminumend bells

• 0.33 to 2 hp, 1800 RPM

• Electrically reversible

• Compatible with SCR (thyristor) DC drives

• Large brushes for longer brush life, witheasy access for replacement

• 90VDC and 180VDC models available

Also Available

56C Gearboxes

Motor Bases(56 - 449T)


1-800-633-0405


Inverter-duty AC motorsMARATHON ELECTRIC inverter-dutymotors have been carefully selected tobe performance-matched with ourDURApulse and GS series AC drives.

• 1/4 to 100 hp

• Dual 230/460V and 575 VAC models

• 1200 and 1800 RPM base speeds

• Factory-mounted encoders onselect models

• NEMA Premium Efficiency XRI seriesfrom 1 to 10 hp compliant with EnergyIndependence and Security Act of2007

General purpose AC motorsIRONHORSE motors are availablein rolled steel (1/3 to 2 hp) and castiron (1 to 300 hp) 1800 RPM models.Selected 1200 and 3600 RPM unitsfor the most popular horsepowerratings start at just $70.

• T-frame cast iron three-phase, 208-230/460V up to 300 hp, TEFC enclosure

• 56C frame rolled steel single-phase,115/208-230V, from 0.33 to 1.5 hp,TEFC enclosure

• 56C frame rolled steel three-phase,208-230/460V, from 0.33 to 2 hp,TEFC enclosure

• TC frame (C-face) cast iron three-phase,208-230/460V, up to 100 hp,TEFC enclosure


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What’s included?• High-performance, certified OPC-compliant connectivity

via Ethernet, with unparalleled compatibility andperformance.

• DL05, DL105, DL06, DL205, and DL405 PLC support through RS-232, RS-422 serial or DirectLOGIC andProductivity3000 Ethernet interfaces.

• DL205, DL405 and Terminator controller remote I/O orAC drive Ethernet interfaces.

• OPC Quick Client application included for testing andeasy troubleshooting.

• Automatically generate tag names by importingDirectSOFT project Nicknames and Descriptions orProductivity3000 Tag database.

Design a low-cost data acquisition or monitoringsystem using KEPDirect OPC Server software andaffordable AutomationDirect control devices.

For complete details or to order, visit:http://www.automationdirect.com/kepdirect

The new streamlined KEPDirect OPC Serverconnects your preferred Windows client software toAutomationDirect communication-enabled devicessuch as programmable controllers, remote I/O andvariable frequency drives (VFDs). This means thatany industrial HMI, SCADA, data historian, MES orERP software package that includes an OPC clientinterface (most do) can connect directly to thosedevices.

Multi-mirror Solar ArrayPleasantville High SchoolPleasantville, IowaProvided by Chip McDaniel,AutomationDirect

he Industrial Technology students at Pleasantville HighSchool, in Pleasantville, Iowa

(southeast of Des Moines), have spentthe last three years building a multi-mirror solar array. Students from fourdifferent technology classes have contributed to the project over the threeyear period; the AutoCAD and draftingclasses have helped design and document the project, students in themetals class performed much of thewelding and other fabrication tasks,while students in the electronics classhave wired the machine and pro-grammed the PLC. Instructor FrankVanderpool has been the teacher andmentor who has championed the projectfrom its inception.

Sunlight is focused on a solar heatexchanger positioned at the focal pointof the array. Water is warmed inside thesolar heat exchanger and then pipedindoors to a storage tank and radiator inthe nearby school shop where it is usedto heat the room, before circulatingback out to the solar heat exchanger tobe reheated.

The array consists of 96 one-foot-square mirrors positioned in a 10x10array. The four mirrors in the center ofthe array were omitted – because theywould always be occluded from the sunby the solar exchanger. The array/exchanger assembly is hinged and fittedwith wheels so that it can track the sunwith both altitude and azimuth motionsduring each day. Two SureStep steppingsystems from AutomationDirect areused to power these two axes of motionvia custom gearboxes designed and builtby the students.

Three simple photo-resistors are

used as sunlight detectors to monitorthe position of the sun.These photo-resistorsare enclosed in narrowtubes, each with a slitfacing skyward. Thetubes are aimed ever soslightly away from theangle of the array - sothat when sunlightreaches the bottom ofthe tubes and excitesthe photo-resistor, thislight signals a need to move the array tokeep alignment with the sun. One

detector is used to monitor the azimuthaxis, as the sun only moves in one direc-tion across the sky each day, but two arerequired for the altitude axis, as the sunrises in the sky during the morning andthen falls in the afternoon.

A DirectLOGIC DL06 PLCaccepts discrete inputs from the sunlightdetectors and uses that information tocontrol the motion of the two steppersystems via H0-CTRIO modules.Additional logic in the PLC is used toapproximately position the array oncloudy days so that if/when the cloudsdissipate the array is positioned to beginits automatic operation. The PLC controls the flow of water through the

solar heat exchanger, and also controls apump inside the storage tank. Analoginputs to the PLC allow the monitoringof temperatures in four locations: at thesolar exchanger, at the point where thewater enters the building, inside thestorage tank, and the temperature of theair inside the shop. Based on the varioustemperatures, the PLC opens and closesa valve to regulate the flow of waterthrough the loop, and most importantlyto stop the flow of water if the array isnot producing heat for some reason(perhaps a cloud is blocking the sunlight). The PLC also controls theflow of water across a second heatexchanger inside the storage tank inorder to maximize the heat transfer intothe storage tank when possible.

On a sunny day the results can bemore than impressive. In fact, on several occasions, the water has boiledand pressurized steam (measured at over104°C) has caused problems such asblown hoses, requiring the team toreevaluate their design and method ofoperation. Other issues involved theinadvertent focusing of sunlight on awooden component which actuallycaught on fire. Today, they have thoseissues resolved and water temperaturesin the storage tank average about 165-180°F even on moderately sunny days.They routinely heat the shop exclusivelywith solar energy throughout the dayand even for a few extra hours after thesun goes down due to the thermal energy stored in the tank.


Student Spotlight


Figure 1

TFigure 2

Continued, p. 29>>

The Future of Technology

28

Don’t size the VFD according tohorsepower ratings. Instead, size theVFD to the motor at its maximum current requirements at peak torquedemand. The VFD must satisfy themaximum demands placed on themotor.

Consider the possibility that VFDoversizing may be necessary. Some appli-cations experience temporary overload conditions because of impactloading or starting requirements. Motorperformance is based on the amount ofcurrent the VFD can produce. For exam-ple, a fully-loaded conveyor may requireextra breakaway torque, and consequent-

ly increased power from the VFD.Many VFDs are designed to oper-

ate at 150% overload for 60 seconds. Anapplication that requires an overload

greater than 150%, or for longer than60 seconds, requires an oversized VFD.Altitude also influences VFD sizing,because VFDs are air-cooled. Air thinsat high altitudes, which decreases itscooling properties. Most VFDs aredesigned to operate at 100% capacity upto an altitude of 1,000 meters; beyondthat, the drive must be derated or over-sized.Be aware of braking requirements.

With moderate inertia loads, over-voltage during deceleration typicallywon’t occur. For applications with high-inertia loads, the VFD automaticallyextends deceleration time. However, if aheavy load must be quickly decelerated,a dynamic braking resistor should beused.

When motors decelerate, they actas generators, and dynamic brakingallows the VFD to produce additionalbraking or stopping torque. VFDs cantypically produce between 15 and 20%braking torque without external compo-nents. When necessary, adding an external braking resistor increases theVFD’s braking control torque — toquicken the deceleration of large inertialoads and frequent start-stop cycles.Determine I/O requirements.

Most VFDs can integrate into control systems and processes. Motorspeed can be manually set by adjusting apotentiometer or via the keypad incorporated onto some VFDs. In addition, virtually every VFD has someI/O, and higher-end VFDs have multiple I/Os and full-feature communications ports; these can beconnected to controls to automatemotor-speed commands.


Tech Brief Cont.Variable Frequency Drives

Web printing presses, paper mills, and material converting applications require the precise speed regulationof closed-loop control. For such cases, VFDs can be run in a closed-loop control mode. Elsewhere,

volts-per-Hertz (V/Hz) and sensorless (or open-loop vector) modes are used.

Figure 4, VFD Control Modes

Most VFDs include several discreteinputs and outputs, and at least oneanalog input and one analog output.Discrete inputs interface the VFD withcontrol devices such as pushbuttons,selector switches, and PLC discrete output modules. These signals are typically used for functions such asstart/stop, forward/reverse, externalfault, preset speed selection, fault reset,and PID enable/disable.

Discrete outputs can be transistor,relay, or frequency pulse. Typically, transistor outputs drive interfaces toPLCs, motion controllers, pilot lights,and auxiliary relays. Relay outputs usually drive ac devices and other equipment with its own ground point,as the relay contacts isolate the externalequipment ground. The frequency output is typically used to send a speedreference signal to a PLC’s analog input,or to another VFD running in followermode.

Typically, general-purpose outputsof most VFDs are transistors.Sometimes one or more relay outputsare included for isolation of higher-current devices. Frequency pulse outputs are usually reserved for higher-end VFDs.

Analog inputs are used to interfacethe VFD with an external 0 to 10 VDCor 4 to 20 mA signals. These signals canrepresent a speed setpoint and/or closedloop control feedback. An analog output can be used as a feedforward toprovide setpoints for other VFDs soother equipment will follow the masterVFD’s speed; otherwise, it can transmitspeed, torque, or current signals back toa PLC or controller.

In Part Two, we will discuss select-ing the proper control mode, understanding your control profilerequirements, and more.

This article originally appeared inthe February 2011 issue of MSD magazine and on:http://motionsystemdesign.com/motors-drives/top-10-specifying-vfds-0211/?imw=Y

Student Spotlight Cont.

Future plans include switching theplumbing over to steam fittings to takeadvantage of the higher temperaturesand pressures which have already beenproven possible. Once they make thatleap, they even envision the potential torun a small steam engine and produceelectricity from the system. FrankVanderpool is understandably proud ofwhat his students have achieved this far.He reports, “The project has been, and

continues to be, a wonderful learningexperience for all of the studentsinvolved. The Multi-Mirror Solar Arrayhas become a symbol of cooperativelearning at Pleasantville High.”




The Future of Technology

ZIPport Multi-Wire Connectors,3 to 108 TerminalsStandard and High ConstructionProfile (HC) Heavy Duty Connectors

Heavy-duty ZIPport connectors quickly and reliablyconnect and/or disconnect wiring in applications such as electronic machinery, robots, and control and signalcircuits.

ZIPport multi-wire connectors range from a small 3-pin configuration to as large as 108-pin configurations. Screw terminal connections are available up to 40 pinsand crimp contact connectors are available from 5 to 108 pins.

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Features • Complete connectors are built from components including

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die-cast aluminum alloy, or self-extinguishing thermoplastic• Single locking system (one lever locked on two pegs) or

double locking system (two levers locked on four pegs)• Operating temperatures from-40°C to 125°C

(-40°F to 257°F)• IP66 degree of protection with enclosure when coupled• NEMA/UL Type 1, 4, 4X, 12 protection when housings are coupled• Conforms with EN61984, VDE 0110, VDE 0627,

EN 175301-801, and UL 1977, UL50, UL50E standards• UL and CE approvals

By Chip McDaniel

BrainTeasers

Shopping Cart Jumble

1.) An engineer went to:www.AutomationDirect.com to purchasesome high-value automation parts. Shepurchased various quantities of three parts:proximity sensors at $50 each, Stablemotor mounting bases at $10 each, andNitra pneumatic fittings at $0.50 each.She purchased a total of 100 parts, andspent exactly $1000 dollars (qualifying herorder for free 2-day shipping). Can you calculate how many of each partshe purchased?

IO, IO, It’s off to Work We Go

2.) A PLC system contains 36 I/O modules and a total of 100 I/O points. Allthe input modules are 4 point, and all theoutput modules are 2 point – except forone 6 point input and one 4 point output.Can you discern the number of input vs.output modules in the system?

Quarter Time

3.) The hopper of a packaging machine isfilled with widgets on Monday morning.Each day the machine packages a singlewidget as a test sample, and then proceedsto package one quarter of the remainingwidgets from the hopper. Recordkeepingis minimal, but it is noted that the num-ber of widgets packaged on Monday andWednesday is exactly 100 more than thenumber packaged on Tuesday andThursday. At the end of the day, Thursday,the production manager asks how manywidgets remain in the hopper. Can you tellhim?

Don’t judge a driver bythe car!

As told by a tour guide at the Edison& Ford Winter Estates Museum in Ft.Myers, FL. The tour guide prefaced thestory by admitting that they couldn’t verify it, so read it at your own risk!

It seems that Henry Ford was drivingon a remote road one day and happenedupon a stranded motorist with a broken-down car by the side of the road. As Mr.Ford was a very competent engineer andmechanic, he stopped to help. Withoutbeing recognized (or introducing himself)he rolled up his sleeves and spent morethan a few minutes diagnosing and ultimately fixing the car’s engine. Once hewas finished, the impressed motoristthanked him, and tried to offer him some

money for his time and effort. Mr. Fordhad to decline the offered money severaltimes saying, “No thank you, I have all themoney in the world – it’s simply not nec-essary.” The motorist apparently got some-what annoyed by that repeated phrase,and finally retorted “If you have all themoney in the world, then why are youdriving a Ford?”

If you are ever in the Ft. Myers, Floridaarea, be sure to visit the Edison & FordWinter Estates. It’s a fascinating museum foranyone interested in technology or history. Learn more at:www.edisonfordwinterestates.org

31


The Break RoomBrainTeasers & Humor

Please visit www.automationnotebook.com to find the answers to these puzzles.

Henry Ford

Use the technology built into the Productivity3000 programmable controllerto make your job easier. Build systems with up to 33 total base groups - one

local and 32 remote (Ethernet). Each basegroup can have up to five local (USB) bases for over 115,000 possible I/O points. The

convenient USB port on each remote slavemodule lets you programand monitor from any remote location. One clickauto-configures all I/Ohardware connected tothe system, including upto 64 AutomationDirectAC drives on the EthernetI/O network, saving hoursof setup. And most analog modules are soft-ware configurable witheasy dialog boxes. TheFREE Productivity Suite software makes it all possible!

Easiest to configure system you’ll ever meet

automation notebook: online technical magazine · 2019-09-06 · automation notebook summer 2011...

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