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Issue 3, 2005 - AutomationDirect

1. with default values that were carefully selected for the U S indus e E o Cumming GA 30040 our new habitat This should belotsof Cooling trial market for out of the box operation DURAPuLse drives ess 20i0 vous 1 191 vsr 1 278 fun considering all the artistic talent on Ta TOE me rean m ave well nae sme Feature Story i o i cost DURAPutse drives with a Marathon Electric motor We havea Phone 1 800 633 0405 interesting stories to tell in our aU Network drive to match every motor we carry and our AC drive and motor or 1 770 889 2858 next issue ieee combos start at 374 For information on DURAPuLsE drives and j mbos Marathon motors get our free catalog or visit the AC Drives Le FAX i 1 770 889 7876 Mean tor youa Nay ang tea Tech nology Brief 20 Motors section of our Web site at puRwus 110 Price 1 208 Price 16100hm Price ar Price new year Safeguarding Your Computer Drive 1800 RPM US 1800 RPM US 1780 RPM US 1800 RPM US www automationdirect com GS3 41P0 Y535 Y536 GS3 42P0 Y368 569 Y551 606 AutomationDirect I Competition E GS3 45P0 Allen Brad DURAPuLsE Drive amp 1336 PLUS I Dive amp Baldor Model 15H Drive Ce tes vee 959 eS 1 087 HP Volt Class Marathon Motor Reliance VS Master Motor amp Baldor Motor GS3 4010 996 1 229 Y5AT 1 311 GS3 4015 5 hp 230 VAC Monday Friday 9 a m to 6 00 p m EST Tech Thr
2. New DataLynx Software offers sse remote data collection and file reporting Safeguarding your Computer Automation Notebook Winter 2005 Issue Three Automation NOTEBOOK Contnbutors Publisher Tina Crowe ManagingEditor Keri Schieber SeniorEditor Jennifer Gerborg Your guide to practical products technologies and applications Editors Note It s a new year and we re busy preparing for this year s show at the Automation Pavilion at National M anufacturing Week M arch 7 10th at Table of Contents New Product Focus 4 DataLynx Software Product Snapshots 6 McCormick Place in Chicago This sara aeehil poe F H i ernet moauies Design Manager Justin Stegall will be our second year there and we ll sink source module for have interactive product demonstra Terminator 1 0 Think and Contributing Writers tions and displays free popcorn and Do Live programming TomElavsky more Stop by our booth number Cover Story 8 Paul Ruland 4311 to learn more about our products The Evolution of Wireless Bob Ogelsby or just to relax and enjoy a cup of coffee Communication Robert Thornton and a snack We look forward to seeing A good thing just got better WAUTOMATIONDIRECT is now offering 25 off our already low prices on the most popular motor and drive combinations Check out our Marathon motor and DURAputsE drive combos and save on your next installation today 100 hp 100 hp To
3. on a number of DiretLOGIC PLCs where other protocols may not be avail able One disadvantage is that data manipulation cannot occur at the bit level Also DirectNET is not an industry standard protocol MODBUSRTU When using DirectLOGIC PLCs MODBUS RTU protocol can be used with RS 232C RS 422 485 4 wire or RS 485 2 wire networks The are numerous advantages to using MODBUS RTU First it is well TXD RXD TXD RXD TXD RXD TXD RXD Signal GND Signal GND Signal GND Connect shield RXD 6 79 O e O TXD oO RXD TXD DL260 CPU Port 2 to signal ground Cable Use Belden 9841 or equivalent 15 TXD DL260 CPU Port 2 RS 485 2 wire Configuration RS 422 networks DirectN ET isan open protocol You can learn the specifics of DirectNET in the user manual DA DNET M which can be found at www automationdirect com DirectNET is an easy to use protocol when used with the DirectLOGIC family of products It is suitable for those applications requiring data to be shared between PLCs or between PLCs and a host computer A network utilizing the DirectNET protocol requires one master station that issues commands to transfer data between the master and slave Examples of master stations are operator interfaces host computers or even another PLC The advantage of DirectNET is that a DirectLOGIC PLC can be the master station Dir
4. Flexible Duct e Sizes from 1 2 to 1 1 2 square Wire Duct Sample Pricing Part Number Price 173 75 Duct Type and Size Rigid 2 25 x 2 25 2M 12 pes 11 2222G Rigid 3 x 4 2M 4 pcs 71 3040G 98 75 Rigid 4 x 5 2M 4 pcs 71 4050G 152 50 Flexible 1 x 1 x 19 7 36 pes DN30AG 189 00 onnection ystems AuTomaTIONDIRECT S Z PLink pre wired PLC cables easily connect 1 0 modules to connector modules for fast easy terminations Connector modules available include feed through AC or DC relay fuse LED diode and more e Cables in 0 5 1 0 and 2 0 meter lengths our website at www automationdirect com Call or go online to request your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com f Order direct by hone aes pN VWAUTOMATIONDIRECT Business Notes Goings On in the Automation ndustry WAUTOMATIONDIRECT 2005 Manufacturing Sector Outlook According to its press release in November the M anufacturers Alliance M API www mapi net projects solid growth in the next two years for the U S economy and expects the manufacturing sector to continue to outpace the overall economy But the pace of growth is likely to decelerate in relation to 2004 at least in the next year T he surgein oil and other commodity prices and rising penetration from imported goods is taking its toll on the indus
5. H aving two IP devices is like having two people that speak languages using the same character set perhaps Spanish and English O bviously we need more Within IP there are several major sub protocols that define the way data is passed T he two that are used most often are TCP and UDP TCP stands for Transmission Control Protocol and isa streaming protocol meaning the connection is like a garden hose You connect to the one device you want data from and each byte put into one end of the hose eventually falls out the other UD P stands for User Datagram Protocol and is packet protocol meaning that the connection is like a mailbox have two Ethernet devices that support TCP IP surely can talk now Sorry same answer Even if we have two people who have functional voices a desire to talk and they both speak English there really is more to a conversation Let s look at ordering a hamburger at a drive through Every restaurant has a slightly different procedure but in general there is a protocol that you follow when you order Being at the right place and speaking the right language isn t enough You must know what to ask for how to ask for it and have the money to pay for it Is protocol important Yeo Try going to a bank and asking for some twenties in a bag to go W hen we access our email or read aweb page weare doing the TCP IP equivalent of going to the post office or library Those TCP IP services have really cryptic names l
6. 0600PL9701 July 2002 ABB prices are from AC 10o March 2000 UL1 077 FIN Cdr Cutler Hammer WMS Supplementary Protectors are used to provide overcurrent b protection where branch protection is already provided or not required They are designed to be applied in conjunction with a branch protector if required and can be a replacement for similarly applied fuses iii Je a p n One two and three pole models i UL1077 UL 1077 recognized e Thermal magnetic overcurrent protection _ 6 to 60 amp ratings _ e Padlocking feature prevents unauthorized operation Se cui Electric uL1077 e Current limiting design for fast short circuit protection 35mm DIN rail mountable amp Cutler Hammer Motor Controls TPIS Wiot The Automation aiiis Filter APF is a high performance surge filter designed to protect electronic loads from surges transients and noise This compactunit is ideal for PLCs robotics and other automation equipment DL205 PLC Powerline a Filter e Single phase 120 or 230 VAC input voltage Low let through voltage e One three and five amp models e High surge current capability e Protection modes L N L G N G e Five year product warranty Call or go online to request your For more information visit www automationdirect com circuit_protection E 1 600 page catalog or www automationdirect com powerandaccessories Teper a ia iim yee gee gs eer
7. 2 supports different types of network interfaces and protocols and has more flexible communications While Port 1 is limited to 9600 baud odd parity and RS 232 serial communications Port 2 supports RS232C RS422 485 4 wire and RS 485 2 wire DL06 and DL260 only networks It supports a variety of protocols K Sequence DirectNET MODBUS RTU Non Sequence ASCII IN OUT and Remote I O on the D L205 CPUs The baud rate can be set from 300 38 4K baud Parity checking and stop bits are user selectable With this flexibility common uses for Port 2 include PLC to PLC communications operator interfaces bar code readers printers load cells serial radio and telephone modems and DirectLO GIC Remotel O In order to fully understand the capabilities of Port 2 let s take a look at the advantages of the different network interfaces and protocols Network Interfaces In the following each of the three networking options available on Port 2 will be discussed Additional 22 information can be found on the Technical Support page at www automationdirect com RS 232C 1 Signal GND RS 232C Configuration Port 2 DLO6 DL250 1 and D260 RS 232C is a simple way to connect two devices that are less than 45 feet apart such as connecting a host computer or an operator interface to a DirectLOGIC CPU RS 232C Configuration RS 232C is capable of operating at data rates up to 38 4 K bps T he data rate may need to
8. Web site and complete the details You can also request FREE stuff including our catalog and our CD ROM featuring the entire catalog and demo software If you provide your email address we will send news and product information from time to time as well For those who prefer to speak with usin person please call 1 800 633 0405 x1845 Thanks for your participation and we look forward to hearing from you Congratulations to all contest winners In the last issue of Automation N otebook we invited readers to locate a hidden Smiley guy hiding in the magazine M any readers cited page 14 as the location but we actually placed him on page 28 Everyone who responded correctly or not was entered for a drawing and winners should have received their prize boxes by now Thanks to all who participated Name Title Company Mailing Address City State Zip Phone Fax Business Type Olena User Oloem O Integrator Clother Primary Product Interest Csend me your monthly e mail newsletter email oO need a full catalog Ol need a catalog on CD with demo software J 1 400 633 0405 Regugsi your FREE coining iwdny E IAM Fax to 770 844 4212 or Mail to 3505 Hutchinson Road Cumming GA 30040 or go online at www automationdirect com www automationnotebook com 31 Reliable circuit protection at AutomationDirect price UL 489 CSA 5 1 AUTOMATIONDIRECT carries products for comprehensive circuit protection rang
9. a clear understanding of the application and with the help of a well trained provider the benefits of wireless communications can now be realized on the factory floor About Tim Cutler Tim Cutler is Vice President of Sales and Marketing for Cirronet He has provided technical sales and marketing expertise Wireless data modems for networking hard to reach PLCs and remote dev Whether setting up an office network or an industrial process our new offering of Cirronet s CR series of serial and Ethernet wireless data modems is a practical solution With 2 4 GHz Frequency Hopping Spread Spectrum Technology a unique Frequency Skip setting to avoid 802 11 Wireless deploy many access points around the technology A mesh network is one in to Grronet since joining the company in CR HN Seri Ethernet LANs 64 hopping patterns and a transmit rate up to i j j November 1998 Mr Cutler has GA TIN SCTICS 1 23 Mbps these field proven performers deliver robust factory typically in the calling pur wmc nar legis a pa significant experience in business to Serial Radio Modem CR SE Series T ane carry the UL FCC and CE marks access points need to be wired to the points ZigBee holds promise for indus business technology marketing having starting at 595 Ethernet Radio Modem network so one of the main benefits of trial sensing applications where a spent 15 years in senior marketing starting at 1 195 wireless wa
10. area of memory My favorite place is in the My Documents folder put all of my DUGCCCCCTT TTT Tee Automation Notebook winter 2005 Issue Three important documents pictures files etc in My Documents This way have one central easy backup area for my data back my dataup onceamonth just in case my computer crashes and chances are it will crash one day Welive in a digital age where most saved data is digital however if my computer crashed and all saved files were lost would lose personal photos equivalent to losing all my pictures in a fire or flood We have the advantage of being able to avoid loss by backing up our data to CDs or DVDs Storage of these backup files which takes hardly any space at all should bein a fire safe or a safety deposit box So use the backup utility that comes with Windows it s fairly intuitive and it will save you lots of pain in the future Lastly one very nice feature of Windows XP and Windows Me is the System Restore feature T his feature will write a restore point when new soft ware or changes to your system occur This gives you the ability to roll back to a previous point when your computer was working hope this information assists you in taking control of your computer Nothing is more annoying and stressful than a zombie computer that doesn t want to execute when you want and need it to perform So go forth and take control of your computer and h
11. as provide relay outputs to activate the fields on the roof Another important feature of the Sprinkool system at GTS is the use of a modem The modem allows for communication with the controller from any location to permit program monitoring troubleshooting and modification when necessary without the need for the expense of a service call Says Smith Prior to themodem if the customer wished to have the system parameters changed or if a sensor went bad wewould have to fly or driveto the site and make the changes We would normally plan to be on site for a couple of days requiring traveling timeand trip expenses With systems located throughout the USA and outside the U SA this cost could prove to be prohib itive Now all of Sprinkool s roof misting systems are installed with a modem which is especially helpful for customers in remote locations Sprinkool also offers the option of incorporating an HMI interface between the PLC and the customer with the use of EZText displays and LookoutD iret software to provide customers with system information alarm notification and to allow customers to modify parameters without fear of altering the basic program T he text panel displays numerical information and allows input from the client and the LookoutD irect software shows customers a graphical view of the system operation In addition to cooling the facility at GTS the Sprinkool system provides the added benefit of ext
12. be reduced depending on the type and length of cable RS 232C isa single ended interface meaning that a single electrical signal is compared to acommon signal ground to determine the binary logic states As a result RS 232C is fairly susceptible to electrical noise RS 422 485 4 wire a Tat TEL Gari m 1 ATE a aTa a i 12 me I y RS 422 Configuration Port 2 DLO6 DL250 1 and DL260 as slave RS 422 485 4 wireisa differential interface which means that logic levels are defined by the difference in voltage between a pair of wires likeT XD and TXD instead of a single signal wire to ground T he advantage of a differential interface is that it is typically more immune to noise or voltage spikes that may occur on the communication lines It also has greater drive capabilities that allow for longer cable lengths RS 422 485 is rated for a maximum cable length of 4000 feet and with the DirectLOGIC PLCs a maximum data rate of 38 4 K bps Again the data rateis highly dependent upon the cable type and length AutomationDirect recom mends using a Belden 9729 or equivalent cable T he advantage of a 4 wire network is that it uses a separate pair of wires for transmit and receive signals As a result timing issues associated with 2 wire networks are eliminated RS 485 2 wire RS 485 2 wire is available on the DL06 and DL260 CPUs MODBUS RTU only Like RS 422 485 4 wire RS485 2 wire is a differential int
13. eae i reproduced or transmitted in any Nay without the prior written consent o New Spherical Optics ae Call or go online to request Automationdirect com Incorporated Technolo for I in To learn more about our line of DURAputse drives visit www durapulse com your FREE 1 600 page catalog Automationdirectretains the exclusive rights Oy g to all information included in this document Small Areas 1 800 633 0405 www automationdirect com WAUTOMATIONDIRECT Order direct by pitone fax or online The Break Room 30 Observations on Turning 50 www automationnotebook com E ge Ftd Anae a GA EA Le EA i New Product Focus what s New WAUTOMATIONDIRECT e L DataLynx Software offers remote data collection and file reporting by Jennifer Gerborg Senior Editor utomationDirect has recently added DataLynx Remote D ata Collection Software to their line of industrial automation products This new software package uses modem technology to provide an inexpensive and simple solution for collecting viewing and storing data from industrial devices regardless of location D ataLynx is the ideal solution for collecting data from remotely located I O devices or for relaying data from multiple stations back to one location It empowers those in charge of plant operations by bringing important information from distant or hard to reach locations right to their fingertips Dat
14. further guarantee that multiple users could operate in the same band T hus spread spectrum held promise for factory floor wireless data applications Because of their lower data rates frequency hopping radios provide better range than direct sequence radios The ability to co locate more radio networks using frequency hopping technology provides more flexibility And without the need for computing intensive protocol frequency hopping radios can be easily connected to devices with limited intelligence Many frequency hopping radios have been designed to work with several industrial communi cation busses such as M OD BUS Factory Floor Communications In 1985 the FCC recognized the potential benefit of spread spectrum technology and the need to use radio transmission for commercial in building communications systens The FCC allocated three separate bands for low powered systems that did not require licensing T he Industrial Scientific and M edical ISM band was broken down into 900 MHz 2 4 GHz and 5 8 GHz H am radio operators were given priority in these bands and non H am operators were required to employ spread spectrum technology As you might imagine use of the ISM band turned into a free for all as a large number of proprietary systems were developed with no interoperability Radios were being designed to maximize performance in specific applications The 900M H zradios were the first tech nology on the mar
15. irect Customer Forums at http forum1 automationdirect com cgi bin U Itimate cgi Information for the N ational Electrical M anufacturer s Association NEMA can be found at their Web site at http www nema org NEM A is also being harmonized with the International Electrotechnical Commission IEC Web site www iec ch and other European standards Additional information can be found at Global Engineering D ocuments Web site at www global ihscom Global Engineering Documents is also the source for obtaining NEMA IEC and CE documents Further information for the National Fire Protection Association NFPA can be found at their Web site at http www nfpa org Some of the more useful publications arethe N ational Electrical Code N EC publication N FPA 70 and also as a good reference refer to the Electrical Standard for Industrial Machinery publication N FPA 79 27 FYI Optical sensors WAUTOMATIONDIRECT New Spherical Optics Technology for Sensingin Small Areas By the Managing Director of AutomationDlrect s sensor supplier he C hallenge Diffuse sensors enjoy great popularity with users W ith diffuse sensors pulsed light from an emitting diode falls on an object of any shape or color and is reflected in a diffuse manner to a light receiver which is located in the same device fig 1 If the intensity of the received light is sufficient the output is switched O perating distances depend on tar
16. missit until it s gone and if you re not careful your data could be gone forever Imagine losing all your sjejc 6 hard work or your digital family pictures because you forgot to or didn t know how to backup and protect your data There are many contributing factors to how or why we lose data and there are many ways to safeguard your computer and gain some sanity in our often too crazy lives First things first every computer should have a good virus protection program There are many to choose from but the most well known are MacAfee and Norton AntiVirus The best part about choosing well known or reputable software vendors is that they are dedicated to keeping up with all the new viruses that continually appear Once you install the virus protection program make sure to keep your virus definition files up to date This is done by going into the virus program and scheduling the program to download updates automatically T hese 20 updated files will keep your computer informed about new viruses T hisis very effective but make sure you schedule the updates for a time you usually have the computer up and running You could also choose to update manually Next make sure you scan your computer This is usually done in the virus scanner program under the virus scan console The virus program can actively protect you against known viruses but what about the ones that might already be on your machine
17. not boast the high potential data rates promised by 802 11b radios it turned out that the high data rates were not needed W hat were needed were radios that could stand up to the high RF noise interfer ence of a factory floor environment be deployed easily and work reliably Radios employing the FH SS technology meet this need today 802 11b has some areas where it performs well on the factory floor The most common is in stock room inven tory applications T he ranges are not as long as those on the factory floor and 10 UWB is a technology that uses a very wide chunk of spectrum but at a low RF power to obtain theoretically extremely high data rates Reports have circulated recently reporting data rates in the hundreds of M egabits per second T he tradeoff will be a very short trans mission range The UWB products currently being tested are focused on location finding devices such as wall stud finders It remains to be seen where UWB will find its niche in industrial applications Conclusion While it has taken some time and caused frustration robust and reliable wireless products are now available for University Mr Cutler holds two patents for microprocessor based design awarded duringhis seven year tenure as a digital design engineer e Reliable data throughput using Cirronet s patented FHSS technology assures reliable performance even in high multipath and noisy RF environments CRC error ch
18. other problens as well It used licensed narrowband technology which operated over a narrow range of spectrum and was 8 susceptible to multipath fading and interference or jamming Multipath fading occurs when multiple copies of the same signal arrive at the receiver with slight differences in timing or phase These differences in timing and phase occur when the radio frequency RF signal reflects or bounces off objects thus taking alonger path than the signal that goes directly from the transmitter to the receiver When the signals arrive out of phase and slightly later in time they tend to reduce the signal strength of the direct path signal causing fading Interference occurs when another device such as a microwave oven gener ates RF frequency noise at the same frequency as the radio TheFCC heaped alleviate another problen faced by wireless communica tion the licensing of radios and the limited availability of frequency licenses To ensure that as many people as possible had a reasonable chance to obtain a license the FCC limited the amount of bandwidth and transmission power for each license To facilitate deployment of these local licenses frequency coordinators were designated to assign licensed frequencies to individual facilities W hile this limited interference it also limited the number of radios a facility could have and the narrower bandwidth resulted in lower data rates AutomationDirect carri
19. protocol makes software development difficult so there is a free software development kit provided by Host Engineering for customers who would like to develop custom applications using ECOM modules N ew Improved Safe for your fine washables TheECOM works very well in applications where a high performance programming or HM I interface is needed or for simple P2P communications H owever if 100baseT is required or if interfaceto non ECOM devicesisrequired the ECOM 100 is a better solution In addition to 100baseT Ethernet the ECOM 100 has a significantly faster CPU which improves performance and enables support of other protocols MODBUS TCP was added for connections to other manufac turer s hardware and anew browser based configuration utility to simplify remote management Supporting other protocols is a significant part of the ECOM 100 design goals A big part of the success of Ethernet is because of its interoperability T he big problem in automation is that most manufacturers like standards so well that they all have their own which of course is an oxymoron Occasionally a particular protocol gains enough acceptance to be considered a de facto industry standard The simplicity of serial MODBUS resulted in wide acceptance and the TCP IP based version MODBUS TCP has also become a de facto standard It bears mentioning that MODBUS TCP is a standard but as there are differences between the English spoken in the U S and i
20. such as the T1K RSSS D2 RSSS and D4 RS The user might also consider an Ethernet solution of ERMs and EBCsas amore efficient approach when remote I O is needed In part 2 of this series we ll be looking at how to set up Port 2 using the DirectSoft PLC programming software The quieter you become the more you can hear Ram Dass 23 Technical Review WAUTOMATIONDIRECT A Condensed Guide to Automation Control System Specification Design and Installation Part 1 System Identification and Safety by Tom Elavsky AutomationDirect ry schematic rey emcees ame wn Lir boolean or PLC Bee fe gry Mri YO NEM NEC mere GRAA IUN iG MOAI SIATE swana ou transformer 7 a fusing gogy shielcecd catshe IEEE circuit breaker photoelectric sensor bhock l aie DE mE ta e Ki WL adure Ehem T DRES Sar d a a aero daeet MCKOBUS HA 485 aoe W tera corral sinking arurang ASCII FID FROCESS pTLA SA ENCODER Arerenoc cue signal conditioner CMI current loop If you have not been directly involved in the world of factory automation data acquisition process instrumentation or electrical controls in general then the above words and acronyms may be somewhat overwhelming But these words and many others are part of the language that s used in the industrial automation world For A Guide to Common Automation Terms refer to http support automationdi rect com docs glossary html The following is a ser
21. try to scan my computer once a month And while we are talking about viruses always be sure you know the person from whom you are opening email attachments too many viruses are prop agated via email by unsuspecting indi viduals O ne astounding virus fact at its peak infection rate 1 in 12 enailson the internet were infected with the M yD oom virus So a good virus protec tion program is a wise investment R Now let s talk about Adware and Spyware Adware usually results from downloading shareware or freeware programs or by clicking that common popup box that says your computer may be too slow click here to speed it up or something to that effect Adware is pretty harmless but excessively annoying and it has been known to slow computer speed to acrawl If you actu ally read the EULA end user license agreement the next time you load a free program instead of just clicking next you will be amazed at what it tells you It basically says you are giving the licenser the right to load anything on your computer So you load a really cool program and then switch to Google to search for something and 20 popup boxes begin streaming on your screen Spyware is installed similarly to Adware but is more malicious in its nature Spyware can be used to log keystrokes remotely access your computer or just cause grief and headaches M uch like virus programs there are several Spyware Adware programs some are free
22. wires In most instances the biggest cost of an industrial control system is the cost of running the wire O ften to run wires or conduit production lines must be stopped resulting in lost production Another benefit of wireless is the flexi bility it provides If lines are changed or moved no wires have to be moved To provide these benefits a wire less solution must be able to cover the distances commonly found in a factory typically hundreds of feet When 802 11b radios were deployed in factories with the expectation that they could cover the range while providing the maximum data throughput they failed miserably The solution was to they are further removed from equipment such as lighting systens welding machines and motor starters that may cause interference With the proliferation of notebook computers and even handheld devices that have PC card slots 802 11b radios can be used as a short range connection to production machinery for diagnostic or configura tion purposes Like the narrowband licensed radios that found their nichein outdoor SCADA applications 802 11b radios have exhibited their usefulness on the factory floor W hat s N ext Already there are two new radio technologies being discussed as the next great thing ZigBee and Ultra Wide Band UWB ZigBeeis designed to bea low power low data rate mesh radio factory floor applications There is not one size that fits all applications but by having
23. 005 Issue Three with the existing conveyor motor Refer to our Web site at http www automationdirect com static specs fujimcselec tion pdf for information on specifying and sizing motor starters Wewill also need to identify where to locate sensors such as limit switches photoelectric sensors proximity sensors etc that will indicate when an operation is completed This is required so our control system knows when to proceed to the next step in our operation As an example we usually need a limit switch to detect when a cylinder is fully extended as in the case when the cylinder is used to push our product onto a conveyor The cylinder fully extended signal is used to de energize the solenoid valve that provided the air pressure to the pneumatic cylinder We also need a limit switch to indicate when the cylinder has fully retracted and provide a signal to the start stop control of the conveyor that the product push cylinder is out of the way for the next product Another appli cation for a sensor is to indicate when the product has reached the conveyor T he sensor can bealimit switch with a roller arm that comes in contact with the product or a photoelectric sensor that can detect the product by using an infrared beam of light The photoelectric approach may be the better choice because the position of the product on the conveyor belt may vary Refer to our Web site at http www automationdi rect com static specs peselectio
24. H 2 ECOM100 module to serve as a client master or as a server slave on a MODBUS TCP IP Ethernet network The H2 ECOM 100 can actively issue MODBUS commands to other nodes or devices on the MODBUS TCP IP network or simply respond to connected MODBUSTCP IP clients Free N etEdit3 software ships with the H 2 ECO M 100 User M anual and is used to configure the modules for a network Flexible addressing allows the choice of protocols and identifying methods Each module can be assigned a number a name or both An IP address is not necessary but can be used if needed for the network NetEdit3 uses two protocols for PC to PLC communications 8 channel sink source module available for Terminator 0O Cumming GA January 15 2005 The T1H 08TDS an 8 channel isolated 2 amp DC output module is now available for AutomationD irect s Terminator field 1 0 a practical network I O solution for remote I O PC based control and distributed control applications The module features electric over current protection and eight fully isolated channels and sink or sourcing wiring options The module has a voltage range of 5 36 VDC Itis priced at 149 New Think and Do Live WinPLC programming pack Cumming GA January 15 2005 A Think amp Do Live software programming pack V5 51 for AutomationD irect s D L205 WinPLC is now available The package offers WinPLC users a low cost development environment with t
25. aLynx uses dial up modems so it s perfect for collecting data from several locations that are miles away says Joey Kulakowski software engineer for BizWareDirect the AutomationD irect technology provider responsible for the devedopment of DataLynx When you have pipes running long distances Ethernet connections become expensive and complicated But phone lines are everywhere they are 4 cheaper and more functional for hard to reach locations With DataLynx remote data from any MODBUS serial enabled device can be viewed and stored in an easy to read format with no PLC programming or SCADA system required The software is capable of collecting an unlimited amount of data from an unlimited number of remotely located devices saving data into comma delimited or tab delimited text files For added convenience D ataLynx runson its own even when a user is not logged into the PC D ataLynx also offers file reporting Reporting allows the user to view and archive the text files that are stored on the PC s hard drive Files can be opened or viewed in Notepad Excel or another program of choice D ataLynx allows the instant retrieval of important industrial data even when phys ical access to the server and industrial devices is not available W ith this product there is finally an inexpensive easy to use application for remote data acquisition says Bill Glover product manager for BizWareD irect T his product is advanced enou
26. and although you have a basic understanding of eec trical control devices you may not have the experience to put it all together Your first option may be to enlist the help of a qualified System Integrator If you do decide to use a System Integrator it would be beneficial to understand as much as possible about automation control system devices and their terminology so that your communications with the System Integrator go faster and more smoothly In most cases special expertise is required to design and install industrial automation control systems Persons without such expertise or guidance should not design and install automation control systems because they can fail and cause serious injury to personnel or damage to equipment The information provided in this series of articles is provided asis without a guarantee of any kind Wedo not guarantee that the information is suitable for your particular application nor do we assume any responsibility for its usein your application It is our intent to produce this series of articles into a usable guide with additional information including a typical real world application that can be followed from concept to completion It is not our intent for the guide to cover every possible topic dealing with automation control systems or to even suggest that the topics being covered are fully detailed Instead the topics are aimed at giving the reader a good starting reference for automated contro
27. and others are at a cost Spybot Search and Destroy 1 3 http www safer networking org is a good free program for combating Spyware and Freeware Lavasoft s Ad Aware http www lavasoftusa com is also a good free program to use One observation about free programs is that while one may find pests and remove them you can install another free program and it will find pests the previous program couldn t T he key to addressing that problem is to use a purchased program Purchased programs seem to find more problems and clean more effectively A program called PestPatrol http www pestpa trol com is a very good program that costs around 39 95 for the home user The key to remember with any ays program is to make sure you keep all the programs up to date All these programs will connect to the Internet and down load their latest updates it s up to you to make sure that happens Viruses and pests will prey on computers that don t keep security holes in the operating systen updated Windows XP machines can benefit from the new Service Pack 2 Update and it s free Service Pack 2 will give you an enhanced Internet Explorer with a popup blocker built in and it also has more personal firewall features Simply run Windows Update on your computer and find out what you are missing Another important defense tool is backing up your data can t stress enough how important it isto keep your datain an easy to access
28. appy computing T he range of what we think and do is limited by what we fail to notice R D Laing New Product Request AutomationD irect is actively adding new products so it can become your one stop shop for industrial automation components We welcome your input we recently introduced wire duct and non metal enclosures largely in response to customer requests If you have suggestions please feel free to jot down the info requested below and fax to 770 844 4212 Or use the Suggest a Product link online at the bottom of our Contact Us page at www automationdi rect com If you need to review our current product offering the best way to do it isto visit www automationdirect com and click on the Site M ap link at the bottom of the home page Product Request Name Company Type of Business Endusr OEM Integrator Othe Product Suggestions www automationnotebook com 21 Tech Thread Serial Ports for DrectLOGI C WAUTOMATIONDIRECT A User s Guide to Configuring Serial Ports for DirectLOGIC PLCs A Two Part Series by Robert Thornton Product Engineer AutomationDirect Part One he capabilities of Port 2 of the T DL06 DL250 1 and DL260 CPUs are often overlooked when designing a process control network Like Port 1 Port 2 can be used for programming the CPU or connecting other RS 232 devices such as an operator interface panel to the PLC Unlike Port 1 Port
29. ating distance 10 20 mm Supply voltage range U B 10 30 VDC Output current 100 mA N o load supply current 15 mA Switching frequency 250 Hz Switching times 2 5 msec M ax ambient light H alogen light 5 000 Lux Sunlight 10 000 Lux Ambient temperature 0 to 550C range D egree of protection IP 67 EMC protection IEC 60255 5 1kV IEC 61000 4 2 Level 2 IEC 61000 4 3 Level 3 IEC 61000 4 4 Level 2 For more information visit AutomationD irect s Web site and search for cylindrical beam 29 and Brainteasers The Break Room Humor ous stories Cartoons WAUTOMATIONDIRECT Observations on Turning 50 by Steve Cleary AutomationDirect turned 50 this year which is not a bad thing am in good health and have a very good life so feel very fortunate Yet I ve definitely noticed some changes was recently at the supermarket and among my purchases was a bottle of wine Displayed prominently was a sign reading We check ID son ALL alcohol purchases have news for you they never check my ID anymore Oh know thisisn t a big deal was asked for my ID less frequently as progressed through my thirties and forties Yes sill get my walle out hopefully anticipating that the clerk will say need to see an ID but never get asked anymore 30 Earlier this year was filling out an application for a passport In the space for hair and eye color instinctively entered Brown for both as
30. ations 3 Think outside the blocks Fred wants to usea pair of wooden blocks cubes to display the day of the month on asimple desk calendar H ow can he number two blocks one number per side so that he can display all the dates of any month 01 31 Bonus puzzle gnoring the many solutions made possible by rearranging a given set of numbers on a block how many ways can he assign the numbers to the two blocks Double bonus W hat is the total number of ways to number the blocks including the rearrangement possibilities Since the mathematicians have invaded the theory of relativity do not understand it myself any more Albert Einstein Please visit www automationnotebook com for brainteaser answers i EPITETTETTTETTE Automation Notebook Winter 2005 Issue Three NOTEBOOK Please tell us whatyou think Log on to www automationnotebook com or send an email to editor automationnotebook com to share comments express an opinion or provide ideas for future issues We invite readers to participate in application stories technical questions and Break Room humor If you have a submission for any of these sections or an article idea please email us All submissions will be reviewed and considered If you are anon subscriber and would liketo beincluded in the next mailing of AutomationN otebook please select Subscription Information on the Automation N otebook
31. blication ACIG PLOOIO EN P August 2003 Prices and specifications may vary by dealer and configuration Prices subject to change without notice All product names trademarks and reaistered trademarks are the property of their respective manufacturers AutomationDirect disclaims any proprietary interest in the marks and names of others 8 ColorSTN Starting at Im 512 KB 1 5 MB max 1 065 Designed and built by www avg net Call or go online to request your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com WAUTOMATIONDIRECT Order direct by phone fax or online WE OOM seni way O OLY H dustma contnals f T ioppipi M Aceves Cog DALE Mirgi rere DOUCCSCCTU TTT IHH Press Releases Product Snapshots WAUTOMATIONDIRECT Screwless terminal blocks added to connection systems line Cumming GA January 15 2005 AutomationD irect now offers screw less terminal blocks including feed through doublelevel oneto two connection two to two connection and knife blade disconnect models along with a line of accessories Screwless clamp technology offers many benefits not found in traditional terminal blocks Without screws connections can typically be made in half the time Wiring occurs on the top of the terminal blocks making it easier for installers to fully insert wires into the spring clamps Screwless terminals also offer vibration proof connect
32. cal M anufacturer s Association NEMA There may also be local regulatory or government offices that can help determine which codes and standards are necessary for the safe installation and operation of electrical control equipment and systems Please keep in mind that if the automated control system you are developing needs to be accepted in the international market the N ational Electrical Code NEC as a publication www automationnotebook com of NFPA is being harmonized with the International Electrotechnical Commission IEC Web site www iec ch and the European H azardous Location Ratings For more information check the Instrument Society of America s SA Web site at www isa org Additional resources on the subject can be found at www ul com hazloc Another area of safety that needs to be considered for automated control systems is lockout tagout procedures as specified by Occupational Safety and H ealth Administration OSHA Lockout tagout refers to specific practices and procedures to safeguard operators and maintenance personnel from the unexpected energization or startup of machinery and equipment or the release of hazardous energy during service or maintenance activities In order to have your control system make use of a lockout tagout procedure the design should include the ability to shut off neutralize or isolate any energy source such as the main electrical feed but also any pneumatic hydraulic or mechani
33. cal energy storage device T he means to do this should be considered in the initial design of the automated control system Additional information can be found on O SH A s Web site at http www osha gov SLT C controlhazardousenergy There are many reasons why the electrical devices that you will use in the design of your automated control system should be listed approved or registered with a testing labora tory One reason is to ensure that the device meets standards that will prevent failure that could lead to catastrophic results Another reason might be for insurance or compliance purposes O ne of the most specified and premier safety testing laboratories is Underwriters Laboratories UL The most applicable area of interest for control systems is U L s Standard for Safety 508A If your control system panel requires being built to UL508A then you will need to contract directly with UL to become a UL508A panel builder or use an existing UL508A pand builder Additional information can be found at http www ul com controlequipment devices html Compliance to UL508A for AutomationD irect products can be found on our Web site at http support automa tiondirect com compliance html The following are other safety points to consider in the design of your automated control system Emergency Stop The control system must provide a quick manual method of disconnecting all system power to themachinery equipment or process T he disconne
34. connected together Protect and connect your In today s market it pays to use quality products ae when building industrial enclosure systems AUTOMATIONDIRECT offers a full line of quality enclosures terminal blocks wire duct ame Enclosures 1 2 rt o Over 1 200 part numbers Description POA CoR es er anda E NEMA 1 wall mount i e Metal and Non Metal 24x24x08 NEMA 12 wall mount Hinged screw cover lift off cover 20 x 16 x 08 a pushbutton console wall mount floor mount free standing and wiring trough i Fans filters vortex coolers light kits locks latches and more Quality manufacturing Robotically foamed in place door gaskets Plasma welded corners Polyester powder coated interior and exterior Stainless steel hinge pins Hubbell Wiegmann rice part number 106 00 N1C242408LP 143 00 N12201608 A 24N24BLP 317 20 A 201608LP 2 028 00 A 606012LP 952 10 A 20H2006SSLP O22 a NEMA 12 free standing mount 60 x 60 x 12 NEMA 4X wall mount 20 x 20 x 06 SSN4202006 3 hole 30mm NEMA 12 31 50 pushbutton enclosure PB3 FS PAI pricas are U S published prices AutomationDirect prices from Volume 9 May 2004 Hotim hit n hotimanonline com pdiL tricep 01 01 04 Prices may vary by dealer Many ot magister rect fr w 01 04 Pr ry by vendors All product names trademarks and trademar
35. ct device or switch must be clearly labeled Emergency Stop After an Emergency shutdown or any other type of power interruption there may be requirements that must be met before the control system or PLC control program can be restarted gt gt 25 Technical Review WAUTOMATIONDIRECT For example there may be specific register values in the PLC memory that must be established or maintained from the state prior to the shutdown before operations can resume There may also be mechanical positions of equipment that have to be moved or jogged to the proper position Accidental Powering of Outputs Do not rely on the automation control system alone to provide a safe operating environment You should use external electromechanical devices such as relays or limit switches that areindependent of any electronic controlling device such as a solid state relay or aPLC output module to provide protection for any part of the system that may cause personal injury or damage T hese devices should be installed in a manner that prevents any machine operations from occurring unexpectedly For example if the machine has a jammed part the controlling system or PLC program can turn off the motor rotating a saw blade H owever since the operator must open a guard to remove the part you should also include a bypass switch that disconnects all system power any time the guard is opened Orderly Equipment Shutdown Whether using a control sy
36. cured to prevent unauthorized personnel from gaining access without the proper tool key or other authorized means 26 Finger Safe and D ead Fronts Another safety area to consider is the use of devices that have finger safe terminal connections which are surrounded by insulated guarding T he use of protective guards over live circuits should also be consid ered even on control panels that have limited access so it is safer for maintenance electricians and authorized personnel to troubleshoot or make adjustments to electrical control devices D ead fronts should be used on control system enclosures where the operator needs to make adjustments to devices such as selector switches thumbwheels potentiometers etc and the controls need to be inside the enclosure so as to protect then from outside weather conditions The dead front is normally an interior door that is mounted in front of the main control panel The outside enclosure door may still require key entry by the operator but the dead front interior door with adjustable devices is interlocked so that it requires a switch to open it disconnecting power to the electrical devices mounted on the main control panel Closed loop Control It is your responsibility in any type of closed loop control system to ensure that if the feed back signal is lost the systen shuts down so as not to cause injury to personnel or damage to the equipment Identifying Process for Automati
37. de enough to allow radio systems to be built with 1M bps data rates In addition 2 4GHz is an unlicensed frequency in most of the world Some disadvantages of 2 4GHz are that it has slightly worse propagation characteristics than 900 MHz Also microwave ovens operate in the 2 4GHz band Nevertheless a large number of radio manufacturers produced 2 4GHz radios The 802 11 Standard When 1 Mbps and 2 Mbps wireless connections failed to gain wide acceptance due to the lack of a standard the EEE created 802 11 a standard for wireless LAN products Note The initial standard had no letter after it The 802 11 standard was estab lished as an after the fact standard encompassing existing products Asa result it was decided to start over and develop a true standard to which new products could be built rather than trying to fit a standard to existing products So work began on the 802 11b standard The 802 11b standard has turned out to be an excellent standard for short range wireless LANs H owever 802 11b products were tried in many applications where their success was very limited The factory floor was one of those less than successful application areas To understand the shortcomings of 802 11b for factory applications it is helpful to understand the benefits of gt gt 9 Cover Story Going Wireless WAUTOMATIONDIRECT wireless on the factory floor First and foremost is removal of the need for
38. ead 22 p Ha he fakes A User s Guide to Configuring Serial Ports for DirectLogic PLCs A Two Part Series www automationdirectcom Ke Schieber M anaging Editor 771 S 2 857 5 GS3 25P0 amp Y543 Black 1336F AQF50 AA EN amp P1861189 1015H205 E amp INGEST 4 10 hp 230 VAC 1 273 4 863 j 7 3 878 GS3 2010 amp Y547 Black 1336F A010 AA EN amp P25G1 1D15H210 E amp IDNM2238T_ 50 hp 460 VAC 2 o E Technical Review 24 6683 4080 amp 872 Blue Max 2900 1996F B050 AA EN amp P40G32 208 1D15H450 0 amp IDM4115 a f 1tor automationn OOK cCOmMm 100 hp 460 VAC 7 439 20 859 25 337 Copyright 2005 Automationdirect com Designing Your Control GS3 4100 amp Y575 Blue Max 2000 1336F B100 AA EN amp P4063207 1D15H4100 E0 amp IDM4400T 4 Incorporated All Rights Reserved S t m All prices are U S list prices AutomationDirect prices are from June 2004 Allen Bradley drives prices are shop rockwellautomation com on yS e 5 24 2004 Reliance motor prices are from Reliance 2004 Industrial Motors amp Drives Catalog Baldor motor and drives prices are from Also available in TEBC Also available in 6 pole 1200 RPM models up to 10 hp and with encoder feedback options Visit our website for availability and prices a f n ae cee einer ee abe be pts are rps eal No parcar nie BEDI ESE Seve Eee FYI 28 TETONAS
39. ecking and ARQ automatic repeat request schemes for auto retransmission of bad packets assures errorless data reception e License free operation avoids the hassles and expense of obtaining an FCC license Celsius harsh environments tools for quick setup requirements UL 2279 listed and CE marked Order direct Ery phone fax or online LEE CHATIEK Siete Waal Copa HEH Ac ogie arg Ge WA A eg een e Rugged packaging well suited to varied operating conditions external radios are housed in NEMA 4X IP 66 enclosures ideal for outdoor and Easy to understand configuration Fully programmable setup to meet specific site and performance 4 k p d iy dustrial coditTila re Ear ae mi agl Base or master Remote or slave Call or go online to request your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com WAUTOMATIONDIRECT en WAUTOMATIONDIRECT PLCs Are Still Preferred by Paul Ruland AutomationDirect Product Manager PLC I O and PC Controls Group Although the North American market for automation and controls has seen nowhere near the growth it did 15 20 years ago programmable logic controllers PLCs are still the preferred controller choice for industrial applications W hat has changed for PLCs are the expectations and desired functionality of their specifiers and users In this edition of PLC Speaking we will discuss some of the results from o
40. ectN ET is available known and widely used in all industries Because of its simple way of transferring data it is up to three times faster than DirectNET It also utilizes CRC error checking making it more robust than DirectN ET which usesLRC error checking Master PLCs There can only be one master on a network with DirectLOGIC PLCs For example aD L06 cannot be the master on a network along with an EZTouch panel on the same network because the EZTouch panel must be the master One solution to this if it is desired to keep Port 1 free is to connect the EZTouch panel to the PLC though a DCM option module or by using available Ethernet options www automationnotebook com Non Sequence N on sequence a non structured protocol allows the CPU to use Port 2 to either read or write raw ASCII strings using the ASCII DL06 and DL260 only and PRINT instructions It can be used with RS 232C RS 422 or RS 485 networks Note there is no provision for multiple stations with the Non sequence protocol Remote I O DirectLOGIC Remote I O is not just a protocol but also a network specification Remote I O is used to communicate with remote 1 0 racks up to 1000 meters away Using Remotel O allows the placement of sensors and other field devices a long distance from the CPU The built in Remote 1 0 master channel has the same capabilities as the RM Net Remote I O master module It can be used with DirectLOGIC Remote I O Slaves
41. ending the life of the roof surface by keeping it at a lower temperature T he heat load has also been reduced sufficiently so that the facility s original air conditioning system has been adequate to cool the interior of the building And most importantly the system requires very little maintenance an important factor for both GTS and Sprinkool 15 CUSTOMER TESTIMONIALS THE MOST PRACTICAL PLC you AUTOMATIONDIRECT SDL205 micromodular PLC series DL isan industry workhorse time tested in some of the toughest is for ni s industrial settings W ith its extensive capabilities for Control Ethernet communication modules for only 299 each can Communications and Connectivity the D L205 can be your be connected to any Ethernet network in your facility s standard PLC choice for almost any application LAN or remote WAN for fast access to critical data There are four DiretLOGIC sie DL205 CPUs e A full set of practical software tools for local data available starting at 125 All are programmed in ladder logic using D irectSO FT 32 Windows PLC Programming software The D 2 260 the newest CPU in the family gives you 30 4 K total memory 16 built in PID loops with auto tune and extensive built in communications capability for just 299 allow the DL205 to provide necessary production data to _ ai The DL205 system provided the j necessary motion control interface to the servo drives along with enoug
42. er versions available now CAT 5e and CAT 6 to name a couple Protocols and Services Would you like fries with that Let s recap A network is like two people communicating Ethernet is one example of hardware used to link nodes into a network In our talking people network example Ethernet might be their voices T here are other ways for those people to communicate such as sign language which would be analogous to other networking hardware People often ask whether Ethernet products from different manufacturers can communicate with each other T he answer is a definite maybe H aving two people with functional voices and a desire to communicate doesn t mean they can In the networking world protocols are like languages and to talk together they must both speak the same language or protocol The most common major protocols on Ethernet are IP and IPX IP or Internet Protocol is the major protocol group DOUCOECCTITTTTTT Aut omation Not ebook Winter 2005 Issue Three that the Internet is based upon and is so named because it provides a mechanism to route between different networks In reality the Internet is a huge collection of small Local Area N etworks or LANs interconnected through IP routers which are devices that provide a bridge between two or more networks Let s say have two Ethernet devices that speak IP can talk yet Again the answer is a definite maybe
43. erface and is rated for a maximum cable length of 4000 feet and data rate of 38 4 Kbps Since it is a 2 wire network the transmit and receive signals are exchanged on the same pair of wires As a result protocol timing can be difficult with some devices To determine which type of serial network to use consider these factors How many devices will be on the network What is the maximum distance W hat are the requirements of the other devices on the network Are you comfortable with handling timing issues that may arise with a 2 wire multi drop network Protocols All of the protocols available have a maximum data rate of 38 4 K bps T hese protocols support half duplex commu nications with D iretLO GIC PLCs K Sequence K Sequence protocol can be used with RS 232C or RS 422 networks K Sequence is typically used to commu nicate to a DiretLOGIC PLC from a ELITE i PPE Automation Notebook winter 2005 Issue Three host computer running D irectSoft It may also be used to communicate between an operator interface acting as the master to a PLC network W hen using K sequence with DirectLOGIC PLCs thePLCs cannot be the master One advantage that K Sequence has is its ability to perform write operations on individual bits such as O points or control relays DirectN ET Like K sequence DirectN ET protocol can be used with RS 232C or Termination TXD RXD Resistor __ _TXD RXD
44. es Cirronet s radio modems As technology improved so did the narrowband radios at least in terms of interference from radios far removed in frequency But the issues of licenses and coordination remained as did the effects of in band interference and multipath fading As a result licensed narrowband radios were used primarily in outdoor applications such as SCADA With outdoor use multi path fading was reduced And since SCADA systems sent small amounts of data the low data rates were need for factory floor wireless communications The Introduction of Spread Spectrum Technology Frequency Hopping Spread Spectrum FH SS technology was developed in large part by the military for secure voice communi cations T hese techniques were classified until sometime after World War II This form of spread spectrum uses a narrow band radio signal but the frequency of the RF signal varies rapidly So at one moment the radio could be transmitting at 915M H z and afew milliseconds later it could be transmitting at 927M Hz Anyone trying to detect and listen to a radio transmission would haveto change frequency at the exact same time and to the exact same frequency as the transmitting radio Another type of spread spectrum technology called Direct Sequence Spread Spectrum DSSS came about after World War II as a result of working with coding and sampling techniques In Direct Sequence a high strength narrow band signal is s
45. fit for the most popular PLCs in the industry We ship all in stock orders the same day and we back up these panels with a 30 day satisfaction guarantee Best of all EZTouch products are supported by AUTOMATIONDIRECT Service which has been voted 1 in the industry three years in a row by Control Design magazine readers Call for your free catalog or go online and learn all about our EZTouch panels Visit www automationdirect com eztouch Features include e Easy to use configuration software e Built in Symbol Factory with over 2 000 symbols e FDA compliant low profile slim bezel e VGA resolution 480 x 640 pixels on 8 10 and 15 units 128 colors on objects and screens e 192 touch cells on most units 15 ColoriFT gt alee Slim FDA 1 MB 2 MB max Other touch panel options available with serial drivers or various network interfaces oo Consult Web site for specific serial driver details N etwork models have a 7 day lead time eirs lo Features AN anade 6 Mono Starting at 6 ColorSTN Starting at T Slim FDA 0 Slim FDA i P aN T fat 256 KB fixed 512 KB 1 5 MB max Touch cells 192 DH Remote I O support Yes FDA compliant Trend graphs Logic expressions Prices 10 Color TFT Starting at Touch panel Slim 1799 Software 512 KB 1 5 MB max 1 and cable Total All prices are UR list prices AutomationDirect prices are June 004 prices Allen Bradley prices are from pu
46. get size color and surface structure Figure 1 The use of diffuse sensors is generally trouble free However a problem appears when devices with very small diameters M5 or less short operating distances and or narrow total beam angle are called for See fig 2 Technical Analysis Conventional diffuse sensors work using optical lenses It should be noted that two optical systems are required in the same device one for the emitter and 28 Figure 2 one for the receiver No appreciable problems arise when scaling down the optics of the emitter and receiver to put into a small housing However there are fundamental limitations The lenses themselves can be reduced in size almost indefinitely but the dimensions of the transmitter and receiver components cannot Light emitting diodes LEDs which are available in very small housing sizes are generally used as the transmit ters These housings are still much too large for really small reflex sensors It would appear the only remaining solu tion would be to change to unhoused chips however their use would add considerable cost Only now can the basic challenge be recognized An optical system is shown to scale in fig 3 additional disadvantage is that the roughly cubic LED chips emit their light more or less uniformly in all directions T he situation is no better on the receiver side One elegant and effective solution for light coupling and shaping ha
47. gh to satisfy users needs yet simple enough that anyone can use it and any facility can afford it D ataLynx is compatible with any industrial device that supports serial MODBUS connections Four packages are available to support up to one five ten or an unlimited number of devices D ataLynx software packages are priced from 395 to 1 495 For more information about DataLynx visit AutomationD irect www automationdirect com or BizWareD irect www bizwaredirect com About BizWareD irect BizWareDirect is a softwaredevelopment firm that specializes in industrial data management BizWareD irect offers affordable easy to use software solutions that increase efficiency by making data more useful and more accessible to those who need it For more information on BizWareD irect or its complete collection of software products please visit www bizwaredirect com or call 770 886 5878 M isquotations are the only quotations that are never misquoted H esketh Pearson EZTouch operator panels for PLC Industrial Networks MODBUS TCP IP e Data Highway Plus Serial drivers include e Allen Bradley Ethernet IP e Modicon DeviceNet e GE Fanuc e Profibus e Mitsubishi e MODBUS Plus e Omron e Siemens AUTOMATIONDIRECT PLCs If you are looking for a practical touch panel our EZTouch line is here to help Loaded with features functionality and communication options itis the per fect
48. h CPU memory to facilitate extensive operator diagnostics and recipe management functions all at an unbeatable price Brian Engle ITS fe B Low PRICES ch Control aa up to 4 bases TTA i E We particularly like the DL205 PLC line for our control systems for the hydro and conventional power generation industries The DL205 line is an extremely cost effective and flexible solution when using independent PLCs for each turbine generator station auxiliary systems floodgate controls and other plant systems Andy Feimster N orth Fork Electric Check out our prices on everything from 1 0 modules to CPUs and you ll see that our every day list prices are the lowest in the industry For instance you can buy two of our DL205 systems for the price of one of Allen Bradley s SLC 500 modular systems of similar configuration Will that help your budget AutomationDirect prices are Volume 9 May 2004 prices Allen Bradley prices taken from Publication ACIG PLO01D Je aoe ee EN P August 2003 Arig EU Technical data from SLC500 Chassis Based Processors Product Data Publication 1747 2 39 CompactLogix5320 Catalog Number 1769 L20 Technical Data Publication 1769 TDO03A EN P November 2000 qa n IOI siei iS vt l w3 Connect MODBUS RTU Master Slave devices inverter drives displays or other controllers directly to the PLC CPU port with no additiona
49. had been doing since applied for my driver s license when was 16 Later that day glanced in amirror and saw a lot of gray hair reluctantly changed my hair color entry to Brown Gray The next morning while was shaving and getting ready to go to the post office took a good look at all the gray was seeing in the mirror crossed out the Brown and just left Gray on my form My passport will be valid for 10 years and it s doubtful that my hair will magically start turning brown again might add that the dutiful some what bored looking civil servant who processed my application smiled broadly and laughed when she saw how had entered my hair color on the form which brings up another observation O ver the years I ve learned that it really helps to have a sense of humor Brainteasers 1 Next Day Air An AutomationD irect purchasing agent flies from our Cumming GA facility to visit one of our vendors on the most economical flight she can find two stops one plane change The average speed of the outbound trip including the stops is 120 mph For the return trip a jet is chartered to deliver all of the urgently needed prod ucts to our warehouse as fast as possible It averages 480 mph on the return trip W hat is the average speed for the entire trip Hint t snot 300 M PH 2 Fill in the blanks Use each of the numbers 1 9 to fill in the blanks and complete a valid pair of equ
50. he same control and connectivity features as the standard Think amp Do Live package for applica tions that do not require separate PC HMI screens The Think amp Do Live WinPLC programming pack features flowchart logic implel O configution WinPLC ModbusTCP Ethernet port and Modbus RTU serial port drivers and OPC Client and server The package is priced at 695 and includes one development system license on CD ROM a Certificate of Integrity and user manual www automationnotebook com Molded case circuit breakers offer circuit protection and save panel space Cumming GA January 15 2005 AutomationDirect has introduced a line of M olded Case Circuit Breakers MCCBs that offers UL489 listed performance for branch circuit overcurrent protection and discon necting means The circuit breakers small size saves panel space compared to standard breakers or comparable fusible devices The MCCBs use patented contact conductor designs featuring high speed blow open action that results in superior perform ance when high level fault currents produce extraordinary electromechan ical forces They also feature advanced arc extinguishing technology and a toggle handle that provides three posi tions on off tripped along with visual indicators Prices for the new line start at 139 A line of accessories is also available for the M CCBs Cover Story Going Wireless WAUTOMATIONDIRECT The Evol
51. hey can be hard wired for simpler applications You will also want to determine if your automated control system will benefit from the use of an operator interface also referred to as a Human Machine Interface HMI If your process requires making changes to setpoint values process time flow rates etc then the useof an H M I is the best way to proceed In these situations you will most likely need a PLC that can easily communicate with the HM device If your application requires keeping data records for reference traceability history trending meeting regulations etc then you should look at using a control system that would fall into the category of a Supervisory Control And Data Acquisition SCADA system M ost of these control systems would be comprised of PLC type 1 0 that interface to a PC with appropriate software Watch for Part 2 on System Specification in our next issue References For information on PLC Logic and Principles by D oug Bell of InterC onnecting Automation PLC training books and training through technical schools and organizations visit http support automationdirect com docs training pdf For Web sites with free tutorials that cover basic electricity principles visit any of the following http www thelearingpit com elec bas theory etbmenu html or http www kilowattclassroom com Index htm or http www mrplc com or http www plcs net You may also want to visit the AutomationD
52. ies with continuation in future issues of Automation Notebook to act as a general guideto the specification design and installation of automated control systems The information and references are presented in a logical order that will take you from the skills required to recognize an operation or process suited for automating to tips on setting up a program to maintaining the control system Whether you are an expert or a novice at electrical control devices and systems the information presented should give you a check list to use in the steps to implementing an automated control system Electrical control systems are used on everything from simple pump controls to car washes to complex chemical processing plants Automation of machine tools material handling conveyor systems mixing processes assembly machines metal processing textile processing and more has 24 increased productivity and reliability in all areas of manufac turing utilities and material processing You may have come to realize that an operation or process used to produce your end product is very laborious time consuming and produces inconsistent results You may have also visualized ways that would allow you to automate the operation Automating the process will reduce the amount of manual labor improve throughput and produce consistent results You may have the skills to develop the mechanical means and select the appropriate equipment to make this happen
53. ike HTTP POP3 and SMTP but beyond the names are really simple concepts TCP IP by itself just tells us how our data is getting from placeto place doing something useful requires a service For twoTCP IP devices to establish a useful dialog they both need to support the desired service Thereis a point to this right Absolutely The bottom line is that all of the complicated terminology is simply describing the hardware protocols and services that network devices use Aswith peopletalking the languages and contexts have to be defined appropriately to the function much like speaking the correct language at the correct time with the goal of getting a large soda and fries Let s look at some Ethernet products offered by AutomationD irect and talk about how they fit the landscape The ECOM Ethernet Communication modules are general purpose Ethernet adapters that allow a DirectLOGIC PLC to connect to an Ethernet network They are lObaseT devices meaning 10 megabits over twisted pair CAT 3 or better cable T hey connect to other 10baseT devices in a star topology through a hub or a switch T hey support IPX and IP protocols www automationnotebook com Control System Diagram with combined Ethernet and Device level Networks and use the packet oriented subgroup of each T he services that they support are proprietary but only to simplify and optimize the modules beyond what existing services would allow Using a proprietary
54. ing from the smallest control circuit to the primary service disconnects in control panel applications When compliance with NEC and UL standards for circuit protection is required choose from the industry s most recognized products including supplementary protectors molded case circuit t e B Fa breakers and powerline filters all at great prices pas AutomationDirect s new offering of Cutler Hammer MCCBs includes the 100A FTN Mapa E G Frame 225A F Frame 400A K Frame and 600A L Frame Standard and flex AMTAA ET ALe LoL shaft handles offer mounting flexibility Accessories include auxiliary con Features AutomationDiRECT Square D UL1077 tacts shunt trips and undervoltage release modules 100A Breaker Features Panel Area mm2 9 g a 9 1 S l Ic KA 480 277V AC UL489 listing e Mounting hardware included List Price sn ee aE 15 to 600 A ratings e Advanced arc extinguishing technology G3P 100 FAL34100 S1N100TL Patented contact conductor design Three position toggle handle 225A Breaker with high speed blow open action on off tripped with visual indicators Panel Area mm2 2 a ey 23 142 17 850 65 miline and loadilugkits included e Manufactured in 1509000 certified Ic KA 480 27V AC 35 ap 25 5 facilities List Price 319 ey 1 650 1 131 G F3P 225 KAL36225 S3N225TW All prices are U S list prices AutomationDirect prices are from Volume 9 May 2004 Square D prices are from Pricing Guide
55. ions and are maintenance free since screw clamps apply constant tension to the wires Feed through terminal blocks connect two wires together and are available in sizes suitable for up to 8 AWG They are sold in packages of 50 in blue or gray Double level terminal blocks offer twice the wiring density of feed through blocks and are available in packages of 25 in gray or blue Cross connected LED and diode style doublelevd 6 models are also available in packages of 10 One connection to two connec tion and two connection to two connection terminal blocks allow multiple wires to betied together by way of multiple spring clamps They are available in packages of 25 LED and diode styles are also available in pack ages of 10 Knife blade disconnect terminal blocks allow fast circuit disconnection without rewiring by using a pivoting insulated knife blade They are avail able in gray in packages of 25 Ground terminal blocks are used to mechanically and electrically connect wires to a DIN rail by means of a conducting clamp foot allowing the DIN rail to function as a ground bus bar Ground blocks are molded in green and yellow to meet international standards T hey are available in packages of 10 A line of accessories including DIN rail end brackets and covers angled support brackets jumper bars and marking accessories rounds out the offering Prices for the screwless termi nals start at 0 48 per piece
56. iscrete analog and temperature modules to choose from at the industry s best prices a AOA ONDIREC j 7 n Pee ge eee AA E p i m Feature Story Top PLC Protocols WAUTOMATIONDIRECT Demystifying Network Communications by Bob Ogelsby Host Engineering or many the world of communications is mystifying shrouded in complexity and unknowns with equal parts science and magic and 100 scary We would like to define some common terms and show you how they fit together so you ll find that networking is no more complicated than ordering a hamburger at a drive through Let s take a journey through the world of networking and see if we can demystify some of the networking products offered in today s industry We ll start with some networking concepts and end with some products that use them And to make this journey as painless as possible we ll start simple and keep it simple The Network In the broadest sense a network is any two things bound together In our case a network is two or more nodes master or slave devices that communicate At its simplest a network could be two people talking on a street corner At the most complex a network could be the entire Internet The only real difference between the two is size and topology A Typical Ethernet System In networking topology refers to the shape of the network or the way the nodes are interconnected When referring to topology you ll hear ter
57. ket The 900M Hz radio by virtue of its lower frequency had better propagation characteristics than 2 4 GHz and 5 8 GH z a fancy way for saying it goes farther H owever the 900M H z band is not as wide as the 2 4GHz or 5 8GHz bands As a result you cannot get as many channe s or as high a data rate at 900M H z A second limitation isthat paging systems operate at a frequency close to the 900M Hz band Paging transmitters are allowed to transmit at up to 3 000 watts By comparison 900MHz systems are limited to 1 watt T hus the potential for interference from paging systems is clearly present even from systems not close by Also 900M Hz is not an unli censed frequency in most of the world so 900M Hz products can only be sold in North America parts of South America and Australia The energence of 900MHz cordless phones that operate in the same frequency band has also caused concern due to the large number of these phones in use Meanwhile 10M bps Ethernet became the standard in office environ ments T hus wireless Ethernet devices www automationnotebook com needed to provide similar speed connec tions to the network Given the FCC rules for the SM bands it was difficult to achieve this level of performance in the 900MHz band Fortunately RF technology had advanced sufficiently so that radios operating in the 2 4GHz band could be produced at a reasonable cost T he advantage of the 2 4G H z band was that it was wi
58. ks are the property of the respective man Steel DIN rail for mounting controllers terminals motor controls and more 35 mm wide 7 5mm or 15 5mm high One meter lengths 15 mm wide 5 5mm high One meter lengths 2 AIDINneciors Terminal Connectors head to head Terminal Blocks e Feed through multi level ground fuse disconnect mini and more e Self extinguishing Polyamide 6 6 plastic Self locking clamps High contact pressure Low voltage drop DiNnectors A B Weidmuller ENCES DN T10 1492 W6 102010 3004 362 MED 2 03 0 28 512 O DN F6 1492 H6 101400 3004171 REIED 51110 O 55 52 O 59 44 Three level DN TLI4SLP sensor block 1492 WTS3LP 157851 2715856 al D 512 60 53 09 O 5737 O with LED indicator DN R3551 199 DR1 51450 0801733 cy Miu 16 74 511 34 512 00 Terminal block 10 AWG Terminal block 1 4 fuse visit DIN rail 2 m sold in 1 m lengths f ETT E ore Comey GT ie epee eye DUGCCCCOUT UT TTT control systems for less Hoffman Price part number an prices are taken from ther part numbers ae available from al tecture ZiR 4 For a complete listing of enclosures terminal blocks wire duct accessories and prices Wire Duct Rigid PVC Duct e UL 94V 0 flammability rating e Sizes from 1 2 x 5 8 up to 6 x 4 e Two meter lengths e Cover included e Single piece quantities available e Full line of accessories
59. l hardware or cost required e Connect bar code readers labelers weigh scales or other ASCII devices to the D2 260 CPU Port 2 or choose a WinPLC PC Control in a PLC Package ae aed eats et CoP rocessor and develop custom data handling of any serial protocol Radio telemetry systems are the E op g system z irel ial Eth ial dial f ical most efficient way to get information winning DL205 WinPLC CPU ae 2 Add wireless serial E thernet radios or a serial dial up modem for practica anane problems offers the best connectivity to other F PLC remote device communications or for remote programming The AutomationD irect D L205 M icrosoft based software includ contre components in the telemetry control ing ata on bord aara mam e Low cost single channel high speed counting or j Shoe Ieee tar prova E Ta single axis pulse output for only 79 or multi channel Call 1 800 633 0405 or go online to www automationdirect com products in other SCAD A our PLC CPUs TheWinPLC starting counting or multi axis open loop motion control y Request a FREE 1 600 page catalog complete with specs pricing and more E E Diversified at only 759 programmed starting at 289 4 Ae i Orde direct by phone fam or online with the easy to use Think amp Do flowchart software can accomplish much larger and more complex control applications that would typically require an expensive dedicated industrial PC e Over 40 varieties of d
60. l systens We will be posting the full version of the guide on our Technical Support Web page as a downloadable document in the near future In this issue we will cover the topics of Safety and Identifying an operation or process that could benefit from automation In upcoming issues we will cover control device specification control system design and construction control system installation and finally control system maintenance T he topics will be broken down as follows Part 1 SAFETY and IDENTIFICATION Part 2 SPECIFICATION Part 3 DESIGN and BUILD Part 4 INSTALL and MAINTAIN es es amp 8 amp 9 E9 a es E 8 e 9 9 9 Automation Notebook Winter 2005 Issue Three The first and most important item to consider before attempting an automated control system or even a simple on off control for a pump is safety both for personne who may be working with or near the automated equipment as well as to prevent damage to the equipment To minimize the risk of potential safety problems you should follow all applicable local state and national codes that regulate the installation and operation of your control system along with the equipment or process it is designed to control T hese codes vary by area and usually change over time It will be your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the lates
61. mes are suggested is typically viewed as the most objective research available For the fourth consecutive year AutomationD irect received the highest service scores of any controls supplier in a variety of categories In 2004 these categories were PLCs Terminal Blocks and I O systems The company also received the second highest score in the O perator Interface category Phase Motion Control appoints Michigan Industrial Controls as its authorized service center Phase Motion Control of Genova Italy has recently appointed M ichigan Industrial C ontrols Inc as its authorized service center for the U S and Canada Michigan Industrial will provide start up assistance repair and replacenent for Phase mass manufactured and custom products M ore information on Phase can be found at www phaseit The Michigan Industrial Controls site is www micph com e 9 Automation Notebook Winter 2005 Issue Three User Solutions Application Stories Controlling Nature s Way of Cooling by Jennifer Gerborg Senior Editor hen conventional air conditioning systems were no longer adequate to cool General Tool Company s GTC facility in Cincinnati OH the company began looking for an alternative solution A roof mist sprinkling systen from Sprinkool Systems International Inc in Killen AL would provide evapora tive cooling of the roof and ceiling zone of the plant to reduce heat build up and the radiant hea
62. ms like daisy chain trunk and taps or star In most cases the topology is defined by the networking hardware and system requirements There are advantages and disadvantages to each topology Some networks Ethernet for example can be configured in different topologies whereas others may be limited to one Two forms of networking are M aster Slave and Peer to Peer P2P In Master Slave only the master can initiate communication Think of a drill sergeant barking orders at a private The private won t speak until spoken to and if he s smart he ll only answer the question he s asked In P2P anyone can talk to anyone ese Picture a group of friends sitting around a table where there is generally more than one conversation 18 going on at atime and a person may be involved in more than one conversation So if a few folks talking make up a network and it really is as imple as ordering a hamburger then what is an Ethernet network and why should you care TheM agic of Ethernet Ethernet The very name suggests magic D ata from the Ether no doubt delivered by fairies or maybe nymphs No not really Ethernet is hardware networking standards that were orig inally invented by Xerox Corporation W ith Ethernet each node has a unique hardware address called a M edia Access C ontrol address or M AC for short Ethernet was designed to be inher ently P2P but it can easily support M aster Slave as well The earlies
63. n England there are differences in the MODBUS TCP of each automa tion company It is safe to say that MODBUS TCP devices from different companies can talk but there may be the occasional difference of opinion as to how something should be pronounced or whether a carbonated beverage should be called a soda a pop or as we say in the South acoke As other protocols become accepted standards in the industry the ECOM 100 will be updated to support them Possible candidates are Ethernet IP and PROFINET Ultimately customer demand will drive the decision In Conclusion Wehear it all the time H ad known how fast cool easy flexible or powerful this was would have used Ethernet along time ago l Il definitely be using it in the future Like so many things in this world networking is really pretty simple when you understand the terminology N ever be afraid to dive in And renember every time you order a hamburger at a drive through you are networking and using a protocol to access a service It s just that simple 19 Technology Brief Knowing how to protect your computer WAUTOMATIONDIRECT Safeguarding Your Computer by Tim Lawrence the IT guy Automation Direct n this day and age it seems most of us spend more time cleaning the little spies and pests off our computers than truly using them for productive work or play One thing you can count on in technology is that you won t really
64. n pdf for information on selecting photoelectric sensors We would continue with this analysis looking at each piece of equipment or component in our system and select a device that could control or sense it Some examples include an electrical solenoid valve to control water used to wash residue from a product or a pneumatic valve to control air pressure to a cylinder operating a gate that diverts product on a conveyor or energizing a control relay to signal that a product is in position on a scale In some instances we may need to vary the speed rate or position of our controlling device such as varying the speed of a conveyor changing the amount a valve opens to control a flow rate or remotely changing the setpoint level for a tank This could be accomplished by using an analog output signal An analog output signal is a varying signal that corresponds to the real value we have determined and calibrated into the device For example a0 to 10 VDC signal could represent a conveyor speed of 0 to 500 feet per minute An analog signal to the speed controlling device for the conveyor motor of 5 VDC would result in a conveyor speed of 250 feet per minute Identifying devices to control motion flow events etc and sensing completion is basically identifying the O inputs and outputs of our control system Once these devices are identified they can be used as the field devices in a PLC based www automationnotebook com system or t
65. on The first tep in configuring an auto mated control system is to identify what can be automated You need to have a good understanding of basic electricity and safety It is also important that you have an understanding of basic hydraulics pneumatics mechanical operating mechanisms electronics control sequences etc and a solid knowledge of the operation or process that you are going to automate You should understand how to control motion and movement regulate the flow of fluids dispense granular mate rials orient parts sense product in position detect when an operation is complete etc As a simple example let s say we have a conveyor that moves our product from point A to point B T he conveyor is powered by a 3 phase AC motor which is turned off and on by a manually controlled motor starter and includes for fire protection both short circuit and overload protection The systen requires an operator standing at the motor starter to watch as the product reaches the entrance to the conveyor and to turn the conveyor on to move the product T he operator must also turn the conveyor off once the product has reached the discharge end To automate the conveyor we will need to replace the manually controlled motor starter with an electrically controlled motor starter including short circuit and overload protection We will need to size the motor starter to work DOUCOCCCTIT a TTT Automation Notebook Winter 2
66. pread using coding and sampling techniques to become a low level wide band signal This makes the signal hard to detect The receiving radio reverses the technique to recover the high strength narrow band signal tolerable But this still lefta DOGCCTCOTT TTT Aut omation Not ebook Winter 2005 Issue Three In addition to making radio signals hard to detect and intercept spread spectrum offered another advantage for factory applications By operating over relatively large chunks of spectrum it was less likely that an interfering signal would block the entire band and that multipath fading would affect the entire band equally In the case of frequency hopping radios if the radios are hopping fast enough over a large enough number of channels other radios could be used in the same area since the radios would only interfere with each other when they were using the same channel at the same time T his might reduce data throughput but would allow communi cations Thus the FCC set a minimum number of channels covering a minimum amount of spectrum and a minimum amount of time in which each channel must be used at least once For direct sequence radios if the signal is spread over a wide enough range the signal intensity will be low enough that its signal will not interfere with other radios Thus the FCC set a minimum amount of spreading to be legal For both methods of spreading the FCC set power limits as a
67. reisa solution Amazing results can be achieved with spherical optics With this technology a sapphire sphere is cut in two in order to separate the transmitter and receiver parts Between the two halves of the sphere there is an opaque layer to prevent an optical short circuit The transmitter and receiver semiconductor chips are mounted as closely as possible to the surface of the sphere As seen in fig 4 the chips LED and photodiode are somewhat off the optical axis Thisis normally a disadvantage in optics but not in this case since the 2005 Issue Three Figure 4 transmission beam and the detection zone of the receiver squint somewhat or cross at a certain distance from the device As a result the detection zone is approximately cylindrical The optical system is vacuum potted together with the electronics modulein transparent resin Figure 5 Figure 6 Figure 7 N otes on performance Fig 5 shows the response curve of a cylindrical beam execution with 10 mm operating distance For compar ison the response curves of other minia ture devices fig 6 and a typical optical fiber fig 7 are also shown Products Two sizes of spherical optics sensors are presently available a 10 mm operating distance and narrowest total beam angle and a 20 mm operating distance with a wider total beam angle Application examples The detection of objects through holes and gapsis very limi
68. s been developed in the form of cylindrical miniature devices in which the lenses have been replaced by concave mirrors The result is impressive with an operating distance of 50 mm H owever the total beam angle of 22 is quite large in fact too large for many applications For light based detection applica tions on a miniature scale optical fibers are very well suited Yet all optical fiber solutions suffer from the disadvantage of a large total beam angle so that the problem is still not resolved T he total beam angle of optical fibersis essentially determined by the numerical aperture of the optical fiber material and therefore cannot be influenced From atechnical point of view the obvious solution when narrow total beam angles are required is to choose lasers However laser devices cannot easily be inserted into small housings In addition there are economic considera tions that currently limit more widespread use of laser devices New technology Spherical optics Figure 3 In this figure the LED chip is extremely large in relation to the lens diameter Inevitably the result is very poor beam quality Both the quantity of output coupled light and the total beam angle on the transmitter and receiver sides leave much to be desired Smaller LED chips could be the solution but these unfortunately do not exist An In view of many unresolved detection problems in the miniature field the
69. s lost And when many access large number of sensors need to be read positions at technology companies including Quadram Corporation NYNEX AuromartionDirect CR Series feature e Transmission at 2 4 GHz the only truly international unlicensed frequency band e Frequency Skip feature that prevents interference with from any co located 802 11 wireless LANs points are needed 802 11b has only at a fairly slow rate Data throughput three non overlapping channels Thus will range up to 250K bps and latencies only three access points could be will vary by network size but will typi deployed in a factory without fear of Cally be on the order of 100 millisec interference onds ZigBee products are expected to In the meantime applications hit the market in volume in the second Business Centers and AER Energy Resources Inc Longrange with high speed ry up to 1 23 Mbps total over the air Remote bandwidth in point to point and Pt multipoint applications up to 1 5 miles farther with high gain antenna e Wide operating temperature range from 30 degrees to 70 degrees Mr Cutler received his bachelor s degree in electrical engineering from the Georgia Institute of Technology He also earned a master s degree in business administration from Georgia State or slave specifically designed for use on the naif or 2005 factory floor were by and large propri etary solutions While frequency hopping radios could
70. sold in quantity 100 Mb Ethermet O and communication modules for DirectLOGIC PLCs Cumming GA January 15 2005 AutomationD irect now offers a 100 Mb Ethernet I O base controller module and Ethernet communication module for the DirectLO GIC line of PLCs Both modules are priced at 299 The H2 EBC100 Ethernet Base Controller module provides a low cost high performance Ethernet link between DL205 I O and a PC based control sytem or WinPLC DL205 DL405 CPUs using AutomationDirect s Ethernet Remote Master module for remote I O The module can also be used to connect DL205 I O to a MODBUS TCP IP client master The module is compat ible with TCP IP IPX and MODBUS TCP IP protocols for flexible PC communications EBC modules support a virtually unlimited number of 1 0 points deterministic I O updates on dedicated networks and fast 1 0 updates lt 1ms per base An on board serial port is available for connection to operator panels ASCII In Out etc PC based control software is available that is ready to use with the H 2 EBC 100 module These packages are equipped with compatible 1 0 device drivers program development tools and run time environments The H2 ECOM 100 supports the industry standard MODBUS TCP IP Client Server protocol in addition to standard IP and IPX protocols This DOUCUCCCIT ITT Automation Notebook Winter 2005 Issue Three allows a DL205 PLC with an
71. stem designed around relays and timers or aPLC an orderly system shutdown sequence should be included in your design If afault is detected then any mechanical motion valve position etc needs to be returned to its fail safe position and the equipment process stopped T hese types of problems are usually things such as jammed parts broken cutting tools bin full etc that do not pose a risk of personal injury or equipment damage If a detected problem would result in risk of personal injury or equipment damage then use other means to deal with it such as applying a brake to rotating equipment to stop it before personnel can come in contact with it Grounding To prevent electrical shock incorporate good grounding practices in the design construction and installation of your system Use protective devices for faulted conductors to prevent fire and also realize that good grounding practices can reduce electromagnetic and radiated noise interference to sensitive electronic devices Control Power Distribution Develop a power distribution scheme in the control system circuitry according to code that ensures all circuits are protected with fusing circuit breakers or other interrupting means coordinated such that only the faulted circuit will be opened de energized allowing other powered equipment and devices to continue to operate Unauthorized Access M ake sure all enclosures and cabinets that have energized circuits are se
72. stry or a specific technology as well as basic technical education For example National Technology Transfer Inc www nttinc com has presented nationwide public and custom seminars for over 20 years on topics ranging from PLCs to tdecommunications and HVAC systems Designed to improve company productivity and safety a hot topic this year will be a review of the changes made to the National Electrical Code including the rules and articles new in 2005 With the flurry of fieldbus networks and control communications protocols comes seminars which explain the technologies and their advantages The PROFIBUS Trade Organization in cooperation with the PROFIBUS Interface Center www us profibus com conducts regional one day technical seminars complete with product displays from several vendors Hands on training with real equipment issomethingthe Web can t surpass yet Learning by doing and being guided by an experienced instructor results in increased knowledge retention and is usually well worth the dollars invested in travel and registration expenses AutomationDirect wins Reader s Choice service awards for fourth year Control Design magazine an Industrial OEM M achine Builder and Integrator magazine performs an annual survey in the late fall each year asking their readers open ended questions on who they feel has the best products and servicesin the industry T his type of survey often called unaided since no na
73. t load of the roof Since 1981 Sprinkool has manufactured roof mist cooling systems that intermittently mist a very small amount of water on and above the surface of the roof to cool and maintain the roof s surface temperature as close to the ambient wet bulb temperature as possible With controllers designed and programmed specifically for roof cooling and with temperature sensors mounted on the roof the system calculates and mists just the amount of water that can be evaporated on the roof at that particular moment of the day All of the water is evaporated almost instantaneously so there is no runoff or wasted water As the water evaporates from the roof s surface it absorbs and carries away into the atmosphere over 8600 BT Us for each gallon misted The system cools the exterior surface of the roof and virtually eliminates the transfer of radiant heat from the roof into the building s interior without raising the humidity within the building The Sprinkool system can be used to reduce the temperature in buildings with or without air conditioning and can also supplement aging or marginally performing A C equipment The systems also help reduce electrical power and maintenance costs of existing A C equipment and to displace or reduce requirements for mechanical A C equipment and insulation in new construction The system installed at GTC consists of a network of hydraulic piping mounted on the roof s exterior The net
74. t revision of these codes Most likely your control system will be dealing with electrical energy so your first goal will be to eliminate the risk of fire and electrical shock to personnal The top organizations that provide applicable standards and codes are listed below but even before you get to this area of safety it would be wise to educate yourself as much as possible about electricity and electrical equipment in general A good understanding of basic electricity including DC and AC theory and practice Ohm s Law etc will go along way in helping you understand the various codes and standards There are many good publications and articles on the subject of basic electricity and some local technical colleges offer courses covering subjects dealing with basic electricity Some even offer courses in Programmable Logic Controllers PLCs which can be very useful when dealing with automated control systems Also many Web sites offer free tutorials covering basic electricity and PLCs It would be beneficial to have some understanding of electronic devices such as the operation of a transistor and other solid state devices as well as understanding of the use and operation of electrical test and measurement instruments such as voltmeters current loop meters clamp on amp meters etc At aminimum you should follow all applicable sections of the N ational Fire Protection Association N FPA fire code and the codes of the National Electri
75. t version of Ethernet used a trunk and tap topology where nodes were connected to arigid cable backbone through vampire taps It was called 10base5 or Thicknet The designation 10base5 literally meant 10 megabits per second over baseband up to 500 meters T he original T hicknet worked but was pretty cumbersome A later version 10base2 used a thinner coaxial cable that was daisy chained connected from point to point T he newer 10base2 was also referred to as C heapernet or Thinnet owing to the thinner cheaper cable T he mog common standards currently in use are 10baseT and 100baseT As before the 10 and 100 refer to the speed 10 and 100 megabits per second respectively The T designation refers to a twisted pair wire Unlike the previous standards that used a trunk and tap or daisy chain the T variants use a star topology with each node connected to a center hub or switch much like the tdephone in your house is connected to a switch at the phone company In fact the earliest 10baseT cables were phone lines and 10baseT was designed with phone lines in mind Every officehad phones even the ones that weren t wired for networks so phone wire offered a great way to network W hilea 10baseT network could be run through a standard 4 wire twisted pair phone line the faster 100baseT required something a bit better A higher quality phone cable called Category 5 or CAT 5 is required for 100baseT and there are even bett
76. tal i Our 100 hp drive amp motor Allen Bradley ou there PLC Speakin 12 drive motor urchased combo price rive Tim Cutler y p g AC moto rS and sensorless SERU DRE individually j ioe SIO ARE Tim Lawrence Another project happening at our ne ey and pplication Tips Steve Cleary headquarters concerns office space We are outgrowing our current facility and E re epanding into an adjacent Business Notes 14 building so our team will be relocating Goings On in the Automation vector drives up to 100 h The new DURAPULSE series drive is built on simplicity and flexi Below is an example of some of the combos we offer A complete listing is available on our Web site bility incorporating feedback from our customers with extensive research and testing in our own drives lab DURAputse offers simple Volts per Hertz control PID functionality and dynamic ee IM Seil TORE ma are ha E Ea ma CONTACTS there shortly In order to make the tran Industry braking as well as sensorless vector control and autotuning and OE NS ee SUS RE RUSS S ERP e JUSS aaaeei OSS Automationdirect com Inc sition more appealing we ve been given i is available with optional encoder feedback for speed control Em i E E a 9 User Solutions 15 GS3 22P0 Y368 509 Y551 546 GS3 23P0 3505 Hutchinson Road free reign to decorate certain areas of Controlling Nature s Way of Little programming is required
77. ted with most diffuse sensors currently on the market The new spherical optics sensors succeed in such applications especially in the case of small diameters or gap widths fig 8 Figure 8 O perating distance independent approach With laterally approaching objects whose distance from the switch cannot be kept constant there can be considerable variations in the switching point The new spherical optics sensors yield much better results fig 9 Longer operating distances than inductive devices Inductive proximity switches are also an option and would be very suit able for solving the problems described above as long as the objects to be detected were electrically conducting H owever their operating distances are very short 0 8 to 1 5 mm and are frequently insufficient The closest www automationnotebook com Figure 9 alternatives are photoelectric devices but the shortest operating distance is about 50 mm Nothing has been avail able for operating distances between 1 5 mm and 50 mm until the new spherical optics sensors which now fill this gap D etection of objects in close proximity The wide beam of conventional photoelectric devices makes the detec tion of objects in close proximity gear wheels grids etc almost impossible This new technology on the other hand gives very good results fig 10 in al ae Figure 10 Technical data according to IEC 60947 5 2 O per
78. tion and HVAC commercial refrigeration controls fire safety systems and security systems Recent tech nology advancements and price reductionsin PLCs especially in the area of communications and lower cost nano and micro class PLC s have made them appealing for these types of appli cations When a 14 I O DiretLOGIC DLO5 PLC starts at 99 and a 36 I O DiretLOGIC DLO6 PLC starts at 199 both with two built in serial communication ports the prod ucts rival the value of any purpose built controller even in medium to high volume OEM applications Process Batch SCADA and RTU systems also have proven to be an increasingly popular application for PLCs This supports the notion that customers realize a traditional DCS system is often not necessary for many of these process based systems Additionally many process and batching systems are no longer being built on site but are rather designed as skid mount sub systems that fit into standard shipping containers which can then be assembled on site as part of the complete control system M odern PLCs with their smaller physical footprint compared to most DCS hardware but with extensive process features such as built in PID and Ethernet communications can easily be installed in smaller enclosures and mounted to almost any size equipment All process and discrete PLC applications showed a significant increase in communication connectivity and data acquisition requirements 15 to 20
79. trial sector said D aniel J M eckstroth Chief Economist for the M anufacturers Alliance M API Economic growth and industrial activity will grow more slowly than we previously expected for the first half of 2005 We continue to expect that business capital investment will be an important contributor to economic growth a sign that business is confident about future business prospects Manufacturing activity should continue to grow faster than the general economy with industrial production growth expected to increase 4 1 percent in 2005 Industrial activity is predicted to accelerate to 5 0 percent growth in 2006 The largest percentage gains will come from a rebound in the high tech sectors of manufacturing Computers and electronic products are expected to rise 13 7 percent in 2005 Real investment in equipment and software should increase 9 3 percent in 2005 and 8 1 percent in 2006 growing several times faster than the general economy Real live training Although there is increasing emphasis on Web based training for industrial personne on technical topics there is still much to be said for live conferences and seminars that continue to be held throughout the United States T here are the national industry trade shows such as National M anufacturing Week and the ISA show which always host a full complement of technical and industry related workshops T here are also increasing numbers of regional seminars focused 14 on an indu
80. ution of Wireless Communication by Tim Cutler Cirronet n 1901 Guglielmo Marconi used M orse code to communicate the letter s This transmission was an analog equivalent of a digital signal By 1914 the Marconi Company was engaged in experimental voice transmis sions that laid the groundwork for broadcast radio With the advent of short wave radio costs came down and reliability went up ensuring commercial viability At first wireless transmission was unregulated but as broadcasting began to develop it became obvious to lawmakers that some type of regulation was needed to provide for orderly use of the airwaves To fill this need the Federal Communications Commission was formed on June 19 1934 when President Franklin Roosevelt signed the Communications Act of 1934 The earliest form of wireless communication on the factory floor was the use of walkietalkies where manu facturing engineers communicated with the maintenance engineers to trou bleshoot production or machine prob lems It was a crude wireless network but a wireless network nonetheless Problems with these networks began to surface as other companies in the area started using the same walkietalkies M essages would be garbled when radios keyed at the same time from multiple locations collided with each othe resulting in misinterpreted messages and forced retransmission of information The first wireless data communi cations had its share of
81. ver 300 readers who participated in our online PLC survey We thank all of you who participated and congratulations to the five winners of the BO SE Wave Radios While reviewing the survey responses we found our readers to be savvy users of PLCs with expertise in all areas of programming communications PID and motion control All respondents but three were involved in specifying recommending or buying PLCs Respondents were also from a diverse set of industries with over 30 opting to write in their specific industry served rather than pick from the standard list PLCs are largely used for machinery and process control applications with over 50 of the respondents selecting one of these application categories Within the machinery and process control category G eneral M achinery General M otion Control and Assembly were the top three applications for PLCs The overwhelming popularity of these mostly discrete applications for PLCs was not surprising but use of a PLC for motion control has continued to show more popularity recently than in years past M otion control interfaces directly from PLCs are becoming more prevalent and often offer a much more cost effective solution than choosing a purpose built motion controller and combining it with a separate PLC for a complete control system Also noteworthy was the significant number of respon dents who wrote in several non industrial applications such as 12 building automa
82. work is essentially a supply line which branches into a number of fields activated by low voltage solenoid valves Each field contains sprayheads specifically designed for roof mist cooling T he fields are turned on and off based on calculations by a program executed in a DirectLOGIC DL205 PLC system with aD 2 240 CPU using information provided by three analog temperature sensors located on the roof Each Sprinkool system has a unique program specifically written for the customer s configuration The sprayheads supports and hydraulic tubing allow for a consistent low trajectory pattern and coverage of the water being misted The PLC is critical to a properly operating system In the past Sprinkool had tested many different brands of PLCs and finally settled on AutomationD irect DirectLOGIC PLCs including the DL06 DL205 and the DL405 series According to Sean Smith VP of Technical Services at Sprinkool We chose AutomationD irect for ease of use reliability and durability of the controllers quick shipping time and the superior technical support provided by AutomationD irect With systems cooling industrial commercial and educational facilities from 8 000 square feet to in excess of 17 acres in size the flexibility of the PLC and the ease to remotely connect multiple controllers is vital The PLC must be able to accept analog inputs www automationnotebook com needed to profile the conditions on the roof as well
83. years ago there was very little automation of the data acquisition portion of a control system let alone performing it solely through the PLC Today with the overwhelming pressure to increase production and reduce downtime and waste and doing so with a reduced workforce data acquisition is often at the forefront of any control systen buying decision With this increased need for data acquisition and connectivity newer PLCs must offer more PC like functions such as expansion for multiple serial ports Ethernet ports larger amounts of data logging memory and instructions for manipulating data through high level array and math instructions The need for PC capabilities in a PLC has resulted in next generation PLCs being designed as ruggedized embedded PCs that can be installed in standard chassis based PLC I O systems The DirectLOGIC DL205 WinPLC with a built in Ethernet port addressable serial port 100 MhzCPU 8MB RAM 8MB ROM and a WindowsCE operating system for easy connectivity to other M icrosoft based systems possesses most of the PC control capabilities within a PLC package There is no indication that PLCs will stop evolving rather they will solve more control and information system needs for both industrial and non industrial automation H owever the desire for a single big black box that does every thing may be replaced by the need for several little not so silent black boxes that can do many things and can be easily

Issue 3, 2005 - AutomationDirect

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