Automation Notebook Fall 2015
Contents
1. 21 User Solutions WAUTOMATIONDIRECT CONVERTING A MILL DRILL AND INSTALLING A VFD By Peter James everal years ago purchased a Wadkin lathe made in England in late 1964 It is equipped with a very special motor that is 220V three phase and 50Hz Because of the special design of the motor it has a long extended shaft that carries the four sheave pulley and because do not have three phase power in my shop some means of creating it locally was needed do have 220V power and the 50Hz design of the motor is not a problem knew about rotary phase converters and so called static phase converters but neither really seemed to fit my needs While doing my research of possible solutions learned about Variable Frequency Drives VFDs This seemed like the answer that needed and further investigation showed that several manufacturers of new machinery were using three phase motors VFDs to provide better control over machine speed soft start programmable acceleration and forward reverse functions looked at several different VFD brands and found the ones from AutomationDirect best fit my application liked the keypad setup and the ease of programming the VFD for my lathe also helpful is the ability to mount the keypad remotely with the optional extension cable even programmed the display to show actual spindle lathe RPMs After had my lathe up and running and found how well the2. AUTOMATIONDIRECT UNVEILS PRODUCTIVITY 2000 PROGRAMMABLE CONTROLLER IEEE d L 1 3 T 2 T 2 2 8 ae gt lt pm ys me 65 bmw 3 u zT E 1 TES T RA i LE ER pre www AutomationNOTEBOOK com Fall 2015 Issue 33 FPUNBPROGESSORgSie SPEEDS PRODUCT ORHERETAVESUPPTEN PG 20 Brandidier s Baobab by Bernard Gagnon is licensed under BY SA 3 0 Its time you get more than you paid for in a PLC Introducing the NEW Productivity pp dg 00000000000 It s not just the low price but the incredible built in features that make our new Productivity2000 a must have controller Why pay thousands elsewhere for features that are standard for our newest PLC including FREE programming software 5 built in communications ports right on the CPU All the communication you need is built right in Modbus TCP IP EtherNet IP and serial devices are supported with no additional modules required OLED real time data displays View accurate process variable data current voltage and temperature as well as system diagnostics on the Productivity2000 hard ware OLED displays No meter required Plus Fffortless PID loops Hexible tag name programming e Auto discovered O Hot swappable modules e Simple VFD configuration Built in data logging Multiple wiring options Web server fun
3. Doug Putnam Pite says Linking our tools and machines to IT systems allows our custom ers to customize data acquisition systems to meet their specitic needs monitor machine performance remotely and compare pertor mance among multiple machines Putnam Pite is director of software development at Owens Design www owensdesign com in Fremont California Owens Design makes high speed material handling equipment for the semiconductor disk drive consumer electronics and solar industries Figure 1 Linking machines to IT systems provides a great deal of information about how and where to deploy idle machines along with information about when it is sate to continue or when there is a need to stop a machine or process points out Richard Clark Wonderware InduSoft technical specialist at Schneider Electric www schneider electric com in the article This information can be used to increase uptime reduce operating costs and provide the ability to make decisions remotely Interfacing with ERP and using JIT or other ordering or supply chain techniques can help match machine production to process line needs Improved product quality is a never ending goal of most production machines and systems Collecting data from machines and sending it to quality FIGURE 1 This 300mm wafer platform is made by Owens Design and is connected to their customer s IT system via a PC and OPC Image courtesy of Owens Design cont
4. We have all this and more As always stop by the ever popular Break Room for our brainteasers and then compare your answers at www automationnotebook com pe TJ Johns Coordinating Editor editor automationnotebook com a y www automationnotebook com Table of Contents New Product Focus 4 AutomationDirect Unveils Productivity 2000 Programmable Controller Product Snapshots 6 e Access Control Barriers e UL 489 Rated Miniature Circuit Breakers and UL 1077 Rated Supplementary Protectors e Harsh Duty Food and Beverage Quick Disconnect Cables e Harsh Duty Photoelectric sensors e High Performance 48VDC Drives e ProSense Flow Transmitters with 4 20mA Output e Liquid Tight Conduit Connectors e New Stellar Full Featured 3 Phase Soft Starters e E Stop Control Stations with Maintenance Lockout Feature Cover Story 8 Linking Machines to IT Systems Business Notes 12 Take a look at our NEWEST collection of videos Automation Cookbook Tech Brief 16 Productivity20008 Features and FAQs Student Spotlight 20 Pulp Processor Speeds Production of Healthy Supplement User Solutions 22 Converting a Mill Drill and installing a VFD Student Spotlight 26 Shier Terror Haunts West Coast Break Room 31 Brainleasers 3 New Product Focus WAUTOMATIONDIRECT AUTOMATIONDIRECT UNVEILS PRODUCTIVITY 2000 PROGRAMMABLE CONTROLLER Prod 00000000000 he Productivity2000 is AutomationDirec
5. AutomationDirect AC motor attached via chain to drive a cylindrical stainless steel heart which has grooves machined in its surface It is surrounded by a mesh that helps grind the pulp into a IMAGE 3 The Penn State Pulp Processor very fine powder and separates the seeds Image 3 One of the neat things about the IronHorse motor is that in addition to being quite rugged it can be wired to either the 110V used here in the United States or the 220V used in Africa reports Andrew Mike Erdman the Director of Engineering Leadership Development program and an Instructor in the Engineering Science and Mechanics department at Penn State Mike reports that the design process has taken several years and more than a few trips to Africa to refine Initial designs were huge bulky weighty and did not work well at all We started about 5 years ago and took a machine to Benin where it was used briefly We watched the machine in operation got feedback from the operators and went to work on improvements Unfortunately one of the issues is that we have such limited supply of Baobab pulp here in the USA that Set a amp a 2 x L3 we need feedback from those users in Africa who need to run the machines for extended periods We are lucky to be able to have enough pulp state side to run it for a minute or two Au
6. AutomationDirect VFD worked out decided to convert my Rockwell ram type radial drill back to three phase and install another VFD on it Because this only has 2 HP motor was able to use a VFD with 120V single phase input and 220V three phase output Again went with AutomationDirect and used a remote control for the forward off reverse and speed controls had been experimenting with the programming chang ing things like the acceleration times method of stopping what the display showed and some of the other programmable functions Once became comfortable with the programming procedure found that could customize the VFD to my exact needs The remote controls that used in both of these installations are simple to build and in fact so simple that called the support team at AutomationDirect to be assured that it was as simple as it looked The support people were able to explain things in a manner that clearly answered my questions 22 E Issues with a milling machine recently purchased a mill drill milling machine patterned after the popular Rong Fu model soon found that there were some issues with the machine that felt could be corrected with the three phase motor VFD conversion Because it is a three pulley two belt drive setup with the center pulley acting as an idler with both belts on it changing the spindle speed requires removing and changing the position of both belts This is very
7. RoHS approved www automationdirect com soft starters www automationnotebook com E STOP CONTROL STATIONS WITH MAINTENANCE LOCKOUT FEATURE IDEM emergency stop control stations are available with button protection shrouds that accept a padlock for safe maintenance lockout Stations are available in IP67 rated plastic starting at 29 or IP69K rated NEMA 6 stainless steel housings trom 125 and are ISO cULus and CE compliant www automationdirect com pushbuttons Cover Story WAUTOMATIONDIRECT LINKING MACHINES TOIT SYSTEMS By Cindy Green AutomationDirect nce upon a time individual machines were stranded on an island or just linked to other machines using a tew discrete and dry contact relays Then came machine to machine data links such as a proprietary PLC based network Today and certainly in the tuture machines are being linked to IT systems Both machine builders and their customers benefit from connecting machines to IT systems The closed systems and proprietary communication protocols of the past and the difficulties they caused have given way to open systems This makes it easier to get connected as today s standard communication protocols and open systems are providing a clear path to integration E m 17 In the Control Design July 2015 Cover story Tear Down This Wall
8. b VAUTOMATIONDIRECT The common senso way to buy industrial controis FREE 2 Day Shipping oroare 00 Over Se Dotais ne Tech 5 ato Hon un Cables Watch Videos Product News Circuit Protection Fuses Horne and Overviews How To Videos Automation Cookbook In depth Product Tutorials Get up to speed quickly with these brief Automation Cookbook tutorial videos Temperature Sensing Object Detection lt F D UL 39 M Motors On Off Control Distance Measuring www automationdirect com videos cookbook FE S AN PITT ID Tosia Il The common very be Duy industrial pontrals Qnis PDF Catalog Catalog Print or DVD Free on DVD Dewstond Prine List Application Sorted Tinis Miro er Sa a lager ey cast MNT You ane tue Hohe ease Yi ean da faith Tech Tips Temperature Sensing How Ta Temperature Sensing FREE g On eders 548 and erenr Ene i Hira How To In dagith a i ite i Tach T perm T T nem ad Cenina Wideocs Product Tutorials Automation Cookbook Series Temperature Sensing Ol POLTOMATIONDIRELT LICAND of the Acme Vateo Cookbook Need 15 megam Nereperatune but doe ker all Thi Pari ater utis BTEGHTIPS TAUTOMATIONDIRECT HOW TO LITOMLATIONEHRECT Temperature Sensing w
9. by a one year warranty FM series photoelectric sensors are cULus CE and RoHS approved www automationdirect com photoelectric HIGH PERFORMANCE 48VDC DRIVES NOW AVAILABLE IronHorse GSD1 series DC drives are high performance Pulse Width Modulated PWM controllers for 12 to 48 volt equipment providing smooth control with high efficiency operation GSD1 series drives are available in 1 8 to 1 2 HP motor rating and 20A 1 4 to 1 HP motor rating versions New models allow jumper selectable 12 24 36 or 48V operating voltage Starting at 115 GSD1 series DC drives are available in open frame and NEMA 4X enclosed styles and all come standard with a speed pot knob and dial plate GSD1 series DC drives are RoHS compliant and are backed with a one year warranty www automationdirect com dc drives Automation Notebook Fall 2015 Issue Thirty three PROSENSE FLOW TRANSMITTERS WITH 4 20MA OUTPUT New FSA series flow transmitters provide a 4 20mA analog output proportional to liquid media flow rate Available in three flow ranges up to 27 the transmitters have a M12 quick disconnect and 3 4 inch or l inch FNPT process connections The integrated check valve design allows the sensor to be mounted vertically or horizontally Starting at 140 FM Series flow transmitters are IP65 and IP67 rated and cULus CE and ROHS compliant www automationdirect com flow sensor LIQUID TIGHT CONDUIT CONNECTORS R
10. closed cabinet When connecting the power cables it is best to use crimp on connectors because the connecting screws on the VFD are relatively small The control cable can be connected directly if you tin the ends of the wires Tinning the ends makes it easy to insert the wires into the terminals on the switches and the VFD and prevent them from becoming crushed by terminal screws You need a means of disconnecting the unit from the power source and it should be protected with a circuit breaker The electric panel is about 5 feet from the VFD and it is on a dedicated circuit so my means of disconnecting is a plug on the end of the power cable and a twist lock outlet When it is unplugged know it is disconnected The keypad is removed from the VFD unit by squeezing the two tabs on the sides and pulling out The cabinet door needs to have three holes drilled to accept the keypad Programming the VFD After all the components are installed and the power and control cables are hooked up the next step is programming the VFD to set up the parameters for the particular installation detailed programming provides the maximum benefit and performance from the VFD The VFD comes with a Quick Reference Card and a user manual Both list the parameters used in programming the VFD The information shown on the motor data plate is the first item to input Once the scheme for programming is understood it becomes easy to customize the VFD to your parti
11. costs of ownership et considering initial price features ease of use reliability and free award winning technical support C more Remote HMI App For only 4 99 you can have remote access and control on the go Available now in your Apple or Android app store Get more than you paid C more AutomationDirect com E o U EA9 PGMSW for use with EA9 series panels only cannot be used with 7 series panels 1 800 633 0405 the 1 value in automation Product Snapshots RECENTLY ADDED PRODUCTS ACCESS CONTROL BARRIERS Contrinex YCA 50 series safety light curtains have configurable operating distances of 1 15 and 10 50 meters and protective heights to 1 232 mm Safety light curtains have Type 4 and Cat 4 Ple safety ratings and are IP65 and IP67 rated Light curtain components start at 350 Starting at 640 YXC series light curtain mirror columns provide multi sided safe guarding of danger zones Access control barriers and accessories are cULus CE and RoHS compliant www automationdirect com light curtains UL 489 RATED MINIATURE CIRCUIT BREAKERS AND UL 1077 RATED SUPPLEMENTARY PROTECTORS Eaton FAZ NA Series UL 489 DIN rail mountable mini circuit breakers are available in single two and three pole models FAZ series UL 1077 supplemen tary protector breakers provide overcurrent protection where branch protection is not required These protectors are available in s
12. garages or other parts of their homes Scott has several pneumatic props that pop out at trick or treaters just like the bigger professional haunted houses Scott builds all of his own props and this year he decided to teach a class about using pneumatics at the convention The prop that Scott chose for his seminar is known as a barrel pop up a simple mechanism that pushes a scary mask up from inside a trash can or barrel A remotely mounted valve is typically triggered by a motion sensor of some sort The air passing through the valve extends the pneumatic cylinder and in the case of the barrel pop up a lever is used to increase the reach and to also give the appearance that the creature is lunging forward out of the barrel toward the unsuspecting trick or treater continued p 28 gt gt Best prices on pneumatics Buy direct and save on high quality components m MIN PNEUMATICS AIR PREP CONTROL VALVES Manual or electrically controlled NITRA s directional control solenoid valve selection offers capacity and form factor flexibility to meet your system configuration needs NITRA pneumatic air prep devices modular design allows for stand alone applications as well as easy field assembly for combining components A Poppet and spool valve Process pipeline e e styles Compact modular valves 3 to 5
13. hydrostatic pressure exerted by the liquid above the sensor 4 20 mA output signal compatible with PLCs panel meters data loggers and other amp x electronic equipment ia Va Intrinsically safe with a 0 25 accuracy standard PRESSURE ProSense pressure switches and sensors monitor hydraulic pneumatic and other process applications reliably and accurately A wide selection of models are available Mechanical or electronic pressure switches for low cost indication and switching Gauge and vacuum pressure transmitters with ceramic or stainless steel sensing elements Digital pressure switches transmitters with integral LCD display Air differential sensors also available Research price and buy at www automationdirect com process controllers See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved com the 1 value in automation 1 800 633 0405 Build your panel for less with AutomationDirect Metal Non Metallic and Disconnect Enclosures We ve got what you need to build your control panel With direct prices fast shipping and free tech support you can count on us for the best value in automation Over 400 subpanels are available to choose from including perforated galvanized and stainless steel WIEG MANN Choose from over 1 600 Hubbell Wiegmann enclosures across NEMA 1 3S 3R 4 4X 6P
14. port models Manifolds silencers e Modular panei Manual toggle rotary cables connectors 2 y push pull and foot pedal Position switches filter regulators brackets valves CYLINDERS TUBING AND FITTINGS NITRA pneumatic cylinders are interchangeable with many other brands offering styles for various application requirements in popular bore sizes and stroke lengths Wide array of choices including Bulkhead unions e Quick disconnect Union straight straight and swivel Non repairable round Dual rod guided reducers Tee elbow Y hose couplings _ body style All stainless round Manual hand valves Brass adapter fittings e Compact pancake style body style Meter in and out flow Nylon and polyurethane NFPA heavy duty standard Position switches control straight and coiled and cushioned end styles tubing Many fitting styles also available in stainless steel AutomationBirect Vs McMaster Carr Grainger MSC Price Part Number Price Part Number Price Part Number 205 e 141 35 127 44 us e 23 31 amp 9 Wa Pneumatics Solenoid Valve i 5 port 2 pos 1 4 NPT AVS 5312 24D Filter Regulator Comb 1 1 4 gauge bracket AFR 3233 Air cylinder nose mount S 3 4 bore 1 stroke A12010SN Nylon tubing 1 4 OD black 100 ft N14BLK100 New NITRA inline pneumatic fitti
15. time consuming and inconvenient Also it had a capacitor start capacitor run motor that while powerful was not smooth running Another issue was a flimsy motor mount that kept bending Replacing the motor and adding a VFD would provide electronic speed and reverse control add soft start and a smoother running motor it also gave me the opportunity to fabricate a stronger motor mount Materials required to do the conversion In order to keep the same size motor 2HP used a char to determine the proper NEMA frame size needed for the replacement motor http www engineeringtoolbox com nema electrical motor frame dimensions d 1504 html If you have a motor with a NEMA frame then all you need to do is get a replacement with the same frame number and it will bolt right in without any modifications The same NEMA frame size can continued 24 gt gt save Money Save Energy with DRIVES and MOTORS from AutomationDirect Variable speed drives can improve your bottom line by reducing your motors energy DuraPULSE AC drives 1 to 100 hp add sensorless consumption An investment of as little as IHI PULSE vector control a removable keypad that stores up 59 can start paying off immediately to four different application programs and built in discrete and analog I O Communicate via built in GSI AC drives 1 4 to 2 hp offer Modbus or an optional Ethernet connection simple Volts Hertz control for general purpose app
16. 12 4 12 and 13 ratings all at prices well below more traditional suppliers Subpanels start at 3 00 P0604 Heat Exchangers for NEMA UL Type 4 amp 4X enclosures Research price buy at Maintains optimum enclosure www automationdirect com enclosures temperature in harsh environments 22 to 70 Watts degree F i Heatpipe technology AutomationDirect Tm Closed loop design Enclosures TKS j Low operating cost and and Accessories Price Part Number Price Part Number low maintenance Easy to mount on only one side of your enclosure NEMA 1 wall mount 1 T1 00 348 1 e Energy efficient uses no more N10242408LP A 24N24BLP power than a filtered fan system Filter free no diminished dur NEMA 12 wall mount 24 s 4 7 Qt str atu cooling capacity 20x 16 x 08 240 00 460 9 tha mages ee Starting at only 1028 TE20 015 17 04 Air Conditioner for NEMA 12 Type Enclosures 1 718 00 2v 3 730 34 www automationdirect com enclosure cooling 2 000 BTU TA10 020 26 04 12002266100 4X wall mount 731 00 1 345 32 Enclosure Heaters for moisture and corrosion control 293620 x 06 SSN4202006 A 20H2006SSLP 9 STEGO touch safe positive temperature coefficient heaters prevent the formation of condensation and provide evenly distributed interior air temperature in enclosures Features include Compact design Built i heat tecti Terminal Blocks Pushbuttons Wire and uncin overhe
17. ACO liquid tight connectors in 3 8 inch to 2 inch thread sizes and insulated or uninsulated styles are designed for use on flexible metallic liquid tight conduit and Type B flexible non metallic liquid tight conduit in outdoor or indoor locations Starting at 1 75 connectors are available in straight and 90 degree models Liquid tight connectors are used to positively bond the conduit to a box or enclosure the connectors are suitable for use in Class Div 2 Class Il Div 1 amp 2 and Class IIl Div 1 amp 2 hazardous locations All models feature a zinc plated steel heavy duty locknut to assure continuity of ground a patented split gland ring slips onto the conduit quickly to grip the jacket of the conduit assuring a perfect seal and preventing pullouts www automationdirect com conduit connectors NEW STELLAR FULL FEATURED 3 PHASE SOFT STARTERS SR55 series three phase AC motor soft starters are available in three frame sizes with 24VDC 110 or 230 VAC selectable con trol voltages and are designed for 17 to 477 full load amps at 200 480 VAC SR55 soft starters provide full motor overload protec tion and built in SCR failure protection The units include a touchscreen for application set up and monitoring programmable ana log and digital integrated Modbus and optional Modbus TCP or EtherNet IP communications Starting at 975 the SR55 series soft starters are UL listed CE REACH and
18. C Simplifies Integration OEMs providing machines with PC based such as Owens Design often link to IT systems using Open Platform Communication OPC The PC makes it easy but others prefer connecting the IT system directly to the PLC Gilson control engineer at Quad Graphics www quadgraphics com located in Sussex Wisconsin employs PLCs to track Duane cylinders in an inventory control system for printing machines and other similar processes The automation of our cylinder storage and retrieval system in Franklin Kentucky was instrumental in reducing processing time increasing throughput eliminating errors and improving safety notes Gilson in the cover story From the time an operator inbounds a cylinder into the storage system until it is processed and sent back to the printing 10 n amp T D Hi WAUTOMATIONDIRECT cylinders are placed on the correct carts for transport says Gilson This prevents accidents when cylinders are misplaced on carts The control system reads the status of the equipment to track the cylinder movement loads the correct job into the engravers controls inventory and ensures the correct cylinders are brought out to both the imaging department and the printing presses According to the Cover Story Quad Graphics starts with RFID scanners from Turck www turck com which they use to scan print cylinders with Turck R
19. FID tags inventory control system Figure 2 These scanners are connected to a PLC based Horstmann Cylinder Storage and Retrieval system Quad Graphics automation controls system ACS uses OPC to read status bits from the PLCs and to write commands to the PLCs The commands can be to pick place cylinders reset faults abort task and retrieve store cylinders The ACS is a custom IT application running on a server Users install and run a client application on their laptop or PC to interface to the ACS a ae m Mi i FIGURE 2 Quad Graphics uses a handheld scanner to read data from an RFID tag affixed to print cylinders allowing inventory tracking Image courtesy of TURCK Automation Notebook e Fall 2015 Issue Thirty three FIGURE 3 STIWA sends production data from its machine controllers to IT systems for analysis optimizing operation Image courtesy of STIWA Enabling data analysis STIWA Automation www stiwa com en home uses PLCs to communicate directly to IT systems In its assembly and process modules Figure 3 and in its automated transport feeding and packaging systems it uses its manufacturing software to collect data directly from PLCs The manufacturing software allows STIWA engineers to use MatLab www matlab com to analyze the large amounts of production data collected This capability increases output by enabling reductions in cycle times through the calcu
20. Object Detection h t One of the most pervasive functions of a control system is detecting the presence of an object There are a myriad of sensing technologies such as inductive capacitive and ultrasonic devices that detect nearness proximity and photoelectric devices that 14 sense presence using light beams Learn about each type of sensing technology and its suitable application spaces see typical ladder logic programming for detecting objects with CLICK Do more and Productivity series PLCs A C Motors On Off Control Most control systems have to make things move and that usually involves motors Learn about AC motor control from a simple switch to full reversing contactor configurations selecting and using contactors and associated circuit breakers overload protectors and surge protectors see typical hardware components and ladder logic programming for motor control with CLICK Do more and Productivity series PLCs Distance Measuring t function involves measuring the actual distance of an object from the sensing E A more advanced object detection point Learn about distance measuring technologies including ultrasonic and laser WAUTOMATIONDIRECT sensors selecting the correct measuring style depending on the environment and object types how to set up and use distance sensors see typical ladder logic programming for distance measuring with CLICK Do more and
21. Productivity series PLCs Got ideas for a Cookbook topic Drop us a note Marketing AutomationDirect com and put Automation Cookbook Idea in your subject line AUTOMATION IDEO COOKBOOK New lower prices on LED message displays Industrial LED message displays keep your plant personnel in the know Our low priced ViewMarq LED message boards can display preformatted and real time factory floor data messages sent by a PLC PC or other master device The text message displays can be controlled by ASCII strings through the RS232 or RS485 port Modbus messsages through the RS232 or RS485 port Modbus TCP messages through the Ethernet port Wall mount brackets for easy mounting The Viewmarq line offers One two and four line displays Viewing distances up to 400 feet and 140 degree viewing angle I RS232 I RS485 and Ethernet port standard on all models 4 NEMA 12 extruded aluminum housings suitable for harsh environments Chain and wall ceiling mount brackets included Six models to choose from NEW a PRICES 18 435 Zine 613 Aine 916 iine 599 EENENNEBENEEP 70 4line 1 551 VIEWMARG LED MESSAGE DISPLAY Use the FREE Viewmarg configuration software online download to configure the display create preview and send messages from a PC or create ASCII strings that can be transferred to PLC instructions to control the Vi
22. at protection and Accessories and Lights Connectors Panel or DIN Rail Mount High heating performance Maintenance free explosion proof 7 options now available S JAGO Starting at only 9 50 0 16240 03 www automationdirect com enclosure heaters com Order Today Ships Today See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved 1 800 633 0405 the 41 value in automation The Break Room BRAINTEASERS 1 Sequential Differential 3 Buying Timing What is the next number in this sequence An engineer purchased 20 items at AutomationDirect com and spent exactly 1 200 She bought at least one each of the 11 following items and nothing else a SureStep 21 stepper motor STP MTR 23055D at 40 a 1211 SureMotion L pitch timing belt 187LO50NG i271 at 5 and a SureMotion XL pitch timing belt 312211 1 70XLO25NG at 2 50 131122271 What were the quantities of the items on gt her order 2 Vexing Hexing List prices as of 4 22 2015 Did you know that AutomationDirect now sells a How many people can understand hex IF only you your math teacher and DEAD wide range of timing belts and pulleys in people can understand hex L and XL sizes We offer pulleys with plain bore QD and taper lock bushings Visit www automationdirect com timingbelts and www automationdirect com A Mathematical Joke timingpulleys for mor
23. ature sensing components includes Compact temperature switches e Thermocouple and RTD probes and sensors Transmitters with integral sensors thermocouple or RTD input e Thermowells and fittings Thermocouple and RTD extension wire FLOW The ProSense FSD Series flow switches and new FSA Series flow transmitters monitor liquid media and provide reliable flow detection for industrial applications NEW FSA Series flow transmitters with a 4 20 mA analog output and 0 to 27 GPM measuring range FSD Series flow switches offered in two flow rates up to 26 4 GPM and include an LED output status indicator Fast response time lt 10 1 for FSA model Integrated check valve prevents back flow in horizontal or vertical mounting IP65 IP67 LEVEL Flowline non contact ultrasonic liquid level sensors use proven technology that won t fail because of dirty sticky or scaling liquids Continuous level measurement switching and level control Automatic temperature compensation for accurate measurement Output options include current voltage frequency and relay Pushbutton configured models or PC configured models using free software ProSense float level switches provide a low cost general purpose solution for single point monitoring of liquid level in a variety of applications ProSense SLT series submersible level sensors provide continuous liquid level measurement using the
24. ctionality e Small footprint 7 slot rack only 10 1 2 wide And with 50MB of user memory USB plug and play programming functionality and a super low cost of ownership the new Productivity2000 is the one you need E s9 vm aa d Cm c Affordable Innovation CPU and I O Comparison Base if required Power Supply CPU 16 AC Inputs 16 24VDC Inputs 8 Relay Outputs 8 Analog Input Channels mA ASCII Comm Module Modbus RTU Comm Module Total System Price with USB Ethernet and Serial AutomationDirect Productivity2000 69 00 P2 04B 2 01 255 00 P2 550 105 00 P2 16NA 69 00 P2 16NE3 51 00 P2 08TRS 199 00 P2 08AD 1 e Built in to CPU e Built in to CPU Allen Bradley CompactLogix N A N A 414 50 1769 PA4 3 160 00 1769 L33ER 286 00 1769 1 16 244 00 1769 1016 301 50 1769 0181 713 50 1769 IF8 737 00 1769 ASCII 701 00 1769 SM2 6557 50 Get more than you paid for www Productivity2000 com 1 800 633 0405 the 1 value in automation Automation Notebook Fall 2015 Issue Thirty three Automation NOTEBOOK Your guide to practical products technologies and applications Contributors Publisher Tina Gable Managing Editor Joan Welty Coordinating Editor TJ Johns Design Manager Justin Stegall Contributing Writers Cindy Green Peter Ja
25. cular needs The programming mode is entered by pressing the Program key on the keypad Selections are started by pressing the enter key and changes are entered using the up down arrows on the keypad followed by pressing the enter key to save the selection The four most commonly used programming sections include motor data motor control remote control activation and display customization Programming section P 8 00 is the display function There are many options here like to use one that shows the spindle or cutter speed in RPMs This is accomplished by entering 02 which shows the output frequency multiplied by a factor That factor is the spindle speed divided by the output frequency This can be determined several ways One way is to use the specifications for the machine which will show spindle speed with the standard motor speed Another way is to use a tachometer to measure the spindle speed at a given frequency used an inexpensive digital tachometer to determine the spindle speed at 60Hz and found it was 485 RPMs 485 divided by 60 gave me 8 08 which entered at P 8 01 The display now shows actual spindle speed for my particular belt and pulley configuration If using multiple belt configurations and you have a chart showing the speed for those at a given motor RPM changing the display to show percentage of RPM works nicely This is achieved by changing the value to 1 66 Automation Notebook Fall 2015 Issue Th
26. custom assemblies S either dead end or feed through Pushbutton selector switches and Starting at standard in both single and two gang pilot light bodies are copper free 88 75 assemblies aluminum XCS 0B1 e Miniature and standard size pushbuttons Operating shaft both pushbuttons and selector switches are stainless steel Research price and buy at www automationdirect com pushbuttons Pushbuttons Pilot Stacklights Visual Signal Devices Audible Horns Lights and Switches Wire and Cable Best in SERVICE 14 YEARS E Order Today Ships Today ae x See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved 1 8 00 63 3 0405 t h e 1 ue i n au to ma t i on Business Notes continued continued from p 12 followed by numerous helpful Tech Tips videos and then the hardware specific How to videos that can get you up and running in minutes So what can you expect in each topic Temperature Sensing r From curing ovens to milk pasteurization temperature sensing and control has become an important part of automation Learn about types of temperature sensors and how they work hardware review of temperature probe and transmitter styles how to select the right temperature sensor for your application see typical ladder logic programming for temperature sensing with CLICK Do more and Productivity series PLCs
27. e contracts Extra comm license er computer Service contracts Pay for software Pay for shipping CPU and 1 0 Comparison Base if required Power Supply CPU 16 AC Inputs 16 24VDC Inputs 8 Relay Outputs 8 Analog Input Channels mA ASCII Comm Module Modbus RTU Comm Module Total System Price with USB Ethernet and Serial modules AutomationDirect Allen Bradley Productivity2000 69 00 P2 04B 69 00 P2 01AC 255 00 P2 550 105 00 P2 16NA 69 00 2 16 51 00 P2 08TRS 199 00 P2 08AD 1 e Built in to CPU e Built in to CPU 817 00 CompactLogix N A N A 414 50 1769 PA4 3 160 00 1769 L33ER 286 00 1769 IA16 244 00 1769 1016 301 50 1769 0W8l 713 50 1769 IF8 1769 ASCII 701 00 1769 2 5555750 Student Spotlight PULP PROCESSOR SPEEDS PRODUCTION OF HEALTHY SUPPLEMENT By Chip McDaniel AutomationDirect tudents at Penn State have been working on a Baobab pulp processor in conjunction with the residents of villages in Benin Malawi South Africa and also in Madagascar Native to Africa Baobab is the common name for the Adansonia tree and the fruit that it bears There has been quite a bit of hype surrounding the health benefits of Baobab in recent years and many pundits have speculated that exports of the powdered form of the fruit co
28. e a piece of 3 8 flexible conduit for protection You only need six of the conductors for the remote These cables are readily available at www automationdirect com and most electronics stores The installation The first thing that needed to be done was to fabricate a new motor mount found the best way to mount the motor was to build a temporary platform for the motor and then lower the mill into posi tion on the motor temporarily moved the old motor out of the way and with the new motor in position determined the size of the new motor mount and the location of the mounting holes used a piece of 4 steel plate and welded on two ears for the hinge bolts then used the mill to machine in the four slots for the motor to ride and adjust in and drilled the hinge bolt holes After applying a coat of paint was ready to install the motor The remote control box was mounted to the mill housing using a piece of 3 angle aluminum This provided a very sturdy mount and placed the controls right up front where they are easy to reach The VFD unit is mounted inside a wall mounted steel cabinet behind the machine It is close enough so that the display can be read easily and the unit programmed using the keypad 24 WAUTOMATIONDIRECT The VFD generates a small amount of heat so installed four soffit vents with a fine screen inside There are two on the bottom and one on each side near the top which allows for air flow within the
29. e information There are only 10 kinds of people in the world those that understand binary and those that don t Visit www automationnotebook com for answers 31 www automationnotebook com Now simply CLI CK for analog The best little PLC keeps getting better T Current Pressure Level ws e N S C1 c x1 x2 x3 PWR m x4 RUN m c2 ERR m x5 X6 PORT XT TX X8 Rx1 c3 TX2 1 RX 2 PORT2 v3 Ya 5 Y6 Connect to lots of process devices with analog I O modules for the CLICK PLC The CLICK PLC now has more ways to help you with simple control applications Monitor pressure level current even thermocouples and RTDs directly Perform simple variable control with analog outputs connected to devices such as drives These high resolution modules offer fast setup no DIP switches with software scaling to make your life and program easier Choose from 4 channel current or voltage in 13 bit 89 each 4 channel thermocouple or RTD in 16 bit 149 each e 4 channel current or voltage out 12 bit 119 each e Combo 4 channel in 2 channel out current or voltage 149 each no PID Also Available stand alone combination CPUs with 2 analog inputs 2 analog outputs 4 discrete inputs and 4 discrete outputs built in starting at 129 00 Order Today Ships Today See our Web site for details and restriction
30. ewmarq Fe am wie gl ir 4 2 Connect to PLCs or other compatible master devices C more touch panels C more Micro touch panels Research price buy at www automationdirect com viewmar Order Today Ships Today See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved com 1 800 633 0405 the 1 value in automation Tech Brief By Jeff Payne Automation Controls Product Manager AutomationDirect WAUTOMATIONDIRECT PRODUCTIVITY 2000 FEATURES amp FAQS t s not just the low price but the incredible posi features that make our new Productivity2000 a must have controller The newest programmable logic controller from AutomationDirect the Productivity2000 P2000 is built around a compact modular form factor that allows both fit and functionality in a small space In this introduction we will discuss key features and answer some frequently asked questions about this mighty mite control sys tem From the built in capabilities of the CPU the documentation at your fingertips with the QR codes to the ultra clear OLED displays that give you more than just module status the features are numerous Let s Talk Price Let s face it when yov re working within a budget you have to make difficult decisions Sacrificing quality is not an option and your time is more valuable than most any line item on your BOM Wit
31. form meaning that you can create as many or as few different data types as you need to suit your application 2 Descriptive naming n fixed address controllers you have entities represented by letters and numbers i e Xl for an input OO 4 13 for an output C200 for an internal control bit or N7 32 for a 16 bit integer entity These are easy enough to work with once you learn them but they mean absolutely nothing with regards to the real world devices they are connected to and controlling Tag based addressing you name the memory location i e SYSTEM START for an Input EXHAST FAN ON continued p 182 17 Tech Brief continued contingud from p 17 for an output PURGE TIMER for a timer QA REJECT for a counter AUTO MODE for a control bit and DWELL TMR PRE for an integer The key benefit is that the programmer is forced into following preferred programming practices and adequately documenting his her project With the Productivity Series controllers the tag name database is always downloaded to the CPU with the project so it is no longer necessary to have an up to date copy of the project file on each computer The user could connect to the PLC with a new laptop and have access to 10096 of the documentation a tremendous benefit when troubleshooting a system Additionally with each project we save a csv file of the tag database in the project folder with the same name as the project This allows the user
32. h AutomationDirect products our custom ers typically pay a fraction of the cost when compared to our major competitors And with Productivity2000 you can rest assured that you have installed a high quality control system to increase productivity saving time and money When comparing basic hardware the savings are obvious however the real savings are in the recurring costs you save when compared to those levied by most of the major suppliers in our market Some of these include Software costs License fees per PC Annual service contract Access to online resources forums firmware downloads etc When shopping for a control solution you need hardware and software you don t need overhead and recurring costs Choosing the Productivity2000 is choosing the lowest total cost of ownership 16 Low initial hardware cost Free shipping Free programming software Free software firmware upgrades Free technical support And as always we provide up front pricing with no strings attached Our feature packed P2 550 CPU is priced at 255 and modules start at just 40 P2 O8NE3 What about Communications One of the staples in the Productivity Series is the CPU s built in communications capabilities Ethernet serial and USB ports along with the protocols needed for connectivity are available as standard High resolution features on this CPU No need to pay extra for Ethernet and USB ports
33. he VFD is truly a better way have three in my shop now and have plans to install two more very soon E 25 www automationnotebook com Student Spotlight WAUTOMATIONDIRECT SHIER TERROR HAUNTS WEST COAST By Chip McDaniel AutomationDirect cott Shier with his namesake organization Shier www shierterror com presented a pneumatics seminar in May 2015 at the West Coast Haunter s Convention IS http hauntersconvention com in Portland Oregon His intent was to expose a group of fifteen Terror Home Haunter students to the capabilities of pneumatic systems as they are often used in haunted houses eem SN re t I eds UL Y TEN NI UN ATARATEN OR T 2 T NN i N NN West Coast Haunter s Convention is presented each year as a charity event that gathers home haunters and Halloween enthusiasts for three days of classes on everything in the haunted attraction industry from makeup and actor training to prop making and special effects The charity raises money year round and all of the proceeds from the convention and other events go to support teachers and other professionals that work with deaf hard of hearing and autistic students throughout the Northwest Home Haunters are those twisted Halloween fanatics that put up elaborate displays in their homes for Halloween Many 26 of them do full walk through attractions inside their
34. ingle double and triple pole models UL 489 mini circuit breakers start at 18 and UL 1077 rated supplementary protectors at 9 www automationdirect com circuit protection 6 HARSH DUTY FOOD AND BEVERAGE QUICK DISCONNECT CABLES Ideal for food and beverage washdown applications these IP69K rated sensor cables have industry standard M8 connectors with open leads or with quick disconnect plugs on each end patch cables Cable lengths range trom 0 6 to 10 meters Cables are UL Listed US and Canada and have a 1 year warranty M8 IP69K rated Q D sensor cables start at 10 and M8 IP69K rated patch cables start at 15 www automationdirect com cables HARSH DUTY PHOTOELECTRIC SENSORS The new FM series harsh duty photoelectric sensors are IP69K rated sensors in three wire NPN or PNP styles and are available in 27 washdown models Ideal for food and beverage applications the 10 30 VDC rectangular sensors are fitted with 316L stainless steel housings and are available in diffuse diffuse with background suppression and polarized retroreflective styles starting at 42 00 through beam models are sold as an emitter starting at 33 00 and receiver starting at 40 separately The harsh duty photoelectric sensors have either an attached two meter output cable or an M8 or M12 quick disconnect All models WAUTOMATIONDIRECT have a selectable light on dark on output setting sensing ranges are available up to 10m Backed
35. inued p 10 gt gt Amazing features Amazing price A N NEW SR55 Series full f d s eries Tull reature X STELLAR AC motor soft starters soft starters Reduce shock and stress on your motor and your wallet with the new SR55 series soft starters The SR55 is fully digital fully programmable and is packed full of amazing features including Starting at 975 00 e Full three phase motor control with thyristors in all three motor phases SR55 soft starters are available in three frames sizes e Built in internal bypass relays and patented with a rated c rrent up to 477A iERS intelligent Energy Recovery System e Frame size 1 17 96A 200VAC 480VAC that reduces energy costs when used on lightly e Frame size 2 124A 180A 200VAC 480VAC d ized mot cadea and Ye age E e Frame size 3 242A 477A 200VAC 480VAC e 24VDC IIOVAC or 230VAC selectable control voltage e Full data logging fault records motor current operational status etc e Integrated Modbus RTU or optional Modbus TCP e Suitable for a wide variety of motor loads and or EtherNet IP communication can be connected in the delta allowing use of e Touchscreen with easy to navigate menu structure a smaller soft starter includes the Automatic Application Setup feature that fully configures the starter for a AS specific application with one entry amp e Programmable analog I O digital in
36. irty three YAUTOMATIONDIRECT a a LI This installation was on a mill drill but the same procedure would be used on most any machine used in a woodworking or machine shop The power from the VFD would go to the three phase motor and the remote control would be mounted in a convenient location and you are ready to go The most important rule for sizing the VFD to the motor is that the VFD needs to be rated at least as large as the motor If you were using a VFD on a machine such as a table saw planer grinder etc then the Reverse function would be disabled by using an Off On switch and only connection to D11 terminal on the terminal strip If the motor runs in reverse when you want it to go forward swapping any two of the power leads from the motor to the VFD will correct this For many years woodworkers thought that the only way to use three phase machinery was to have three phase power from the electric company or use an expensive and inefficient rotary converter or a static converter that only allowed the motor to operate at 2 3 of its rated output For motors up to modern VFDs have the ability to take single phase electricity convert it to three phase with full power speed control reversing ability and more The VFD is really a changer for anyone restoring old machinery or dealing with methods of speed control such as Reeves drives and variable diameter pulleys T
37. ith a CLICK PLC Productivity R E Protect your plant and your budget with control stations from AutomationDirect Emergency Stop Control Stations IDEM E Stop control stations provide robust emergency stop protection for exposed conveyors machinery etc LED and protection guard options are available and both the ES and ESL series feature a lid safety trip mechanism for added safety 3 or 4 pole positive guided contacts Operational rating 240VAC 120VAC 6A Plastic housings IP67 or stainless steel 316 housings IP69K Conformance to ISO 13850 IEC 60947 5 1 and IEC 60947 5 5 40mm twist to release mushroom head operator Lid safety trip mechanism ensures the safety contacts will open if the lid is removed Optional E Stop lock off protection guard accepts a padlock to lock out equipment for maintenance activities Starting at 29 00 ES P 230001 Hazardous Location Control Stations Killark control stations are designed to contain and extinguish explosions making them ideal for installations in refineries chemical and other processing facilities where flammable materials are present KILLARK FXCS Series Factory Sealed KILLARK XCS Series Unsealed Eliminates external sealing External sealing required Device bodies and covers are cast NEMA 3 weatherproof copper free aluminum alloy in a wide i Cast conduit hubs 1 2 3 4 and 1 assortment for
38. lation of time optimal trajectories for the modules Every second STIWA s system collects over one megabyte of raw production data including torque noise and a variety of other module measurements The dota is filtered processed and analyzed using a variety of algorithms to establish suitable tolerances modify production process variables or compute time optimized motion tracks for robots and other transfer systems These algorithms were originally written in structured text within the PLC As the algorithms became more complex this method was found to be slow With the connection to the IT system STIWA engineers can import machine and product data into MatLab to visualize the data and to identify problems and optimization opportunities In the Control Design article Martin Werner states To be effective our algorithms must analyze a huge amount of data in near real time Werner is a software tools development engineer at STIWA We www automationnotebook com achieved this high level of performance by optimizing our MatLab algorithms For decades many options have been available for machine builders to implement remote access but improvements are providing faster implementation improved security and wider access E 11 Business Notes 12 TAKE A LOOK AT OUR NEWEST COLLECTION OF VIDEOS AUTOMATION COOKBOOK utomation Cookbook is a collection of short video chapters covering a wide variety of automa
39. lications e lronhorse DC drives can accommodate 1 50 HP Built in Modbus communications I2VDC all the way up to 3HP 240VAC capability and programmable preset IRONHORS These drives deliver excellent low speed control speeds increase their flexibility and stability and are easily configured for your application 2 e GS2 AC drives 0 5 to 10 hp feature Gt built in PID control dynamic braking NEW 48VDC version now availabe with jumper and Modbus communications selectable 12V 24V 36V or 48V operating voltage Research price and buy at www automationdirect com drives With huge selection of high quality industrial electric motors and the lowest prices to go 533 Rolled steel general purpose 1 3 to 2 hp i V with them we have what you are looking for IRONHORSE steel general purpose 1 3 to 2 hp ON Cast iron general purpose 1 to 300 hp 2 MABATHON Farm duty 2 to 5 hp Inverter Vector duty 1 4 to 100 hp 1800 RPM with 1200 and 3600 RPM units 1200 and 1800 RPM base speeds available in the most popular horsepower ratings e Dual 230 460V and 575 VAC models Premium efficiency models meet current NEMA pie M nm T standards from to 150 hp Factory mounted encoders on selec odels ui iid lronhorse DC motors are available in TENV NEMA Premium Efficiency XRI series from and TEFC rolled steel enclosure styles Their to 10 hp compliant with Energy space savi
40. mes Chip McDaniel Jeff Payne Contacts Automationdirect com Inc 3505 Hutchinson Road Cumming GA 30040 Phone 1 800 633 0405 or 1 770 889 2858 1 770 889 7876 Monday Friday 9 00 a m to 6 00 p m EST www automationdirect com Copyright 2015 Automationdirect com Incorporated All Rights Reserved No part of this publication shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated Automationdirect retains the exclusive rights to all information included in this document 1 you are a non subscriber and would like to be included the next mailing of AutomationNotebook please visit http library automationdirect com information should be free and complete the details You can also request FREE stuff including featuring the entire catalog and demo software 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 us in person please call 1 800 633 0405 x1845 Thanks for your interest and we look forward to hearing from you Editor s Note That s not a good idea Recently while traveling along the Georgia coast my wite and happened ee a upon Memory Park Christ Chapel With signage calling it The Smallest Church in America Agnes Harpe
41. ng designs feature a NEMA 56C Independence and Security Act of 2007 flange and removable mounting base Research price and buy at www automationdirect com motors com Order Today Ships Today See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved 1 800 633 0405 the 41 value in automation User Solutions continued continued from p 22 have different horse power different base RPMs and be either single or three phase The NEMA 145T model MTCP 002 3BD18 motor from AutomationDirect most closely matched the metric motor on my mill Because was replacing the Des MAD ws VAUTOMATIONDIRECT motor mount anyway the difference in mounting holes for Autom Direct the motor base was not a problem chose to use the GS2 22PO VFD from AutomationDirect rated with 2HP also used the optional extension cable GS CBL2 1L to allow mounting of the keypad on the outside of the door of the Hubbell Weigmann N1C121208 steel enclosure motor For the remote control unit to be mounted on the mill drill itself used an SA 106 40SL enclosure a GCX1370 22 forward off reverse switch and an ECX2300 5K potentiometer The cable that powers the VFD is a 12 3 SOOW SO cord and a 14 4 SOOW SO connects the VFD to the motor To connect the VFD to the remote control used an 8 conductor 24 gauge Ethernet computer cable run insid
42. ng the components together Configuring VFD parameters from the PLC software saves you time during initial setup However you also get the added benefit of storing those parameters in the PLC project file If you have to replace a drive in the field the current configuration is retained in the project and can be transferred to the new drive saving you even more valuable time when a machine is down GSR read and GSW write instructions are designed specifically for controlling the GS Drives making programming and startup a snap For additional information on using GS Drives with the Productivity Series controllers please view our video series https youtu be 82eX71 qblig Is there an easy way to get started on evaluating the Productivity2000 Yes The ProductivitySuite programming software is and has always been a free download from our Web site We encourage any new user to download the program and click around to see if you like the look and feel it has a very detailed Help file which addresses questions on how the system works Download today http support automationdirect com products p3000 html Once you ve made a decision to purchase and evaluate the Productivity2000 hardware we make getting started very simple with our convenient starter kit P2 START WAUTOMATIONDIRECT O This comes complete with P2 04B 4 slot base P2 01AC 110 VAC power supply P2 550 CPU P2 O8SIM input
43. ngs make it possible to perform all pneumatic functions at any point in the circuit New NITRA coiled nylon hose comes with spring guards to resist kinking and male NPT swivel fittings Hose kits also available and include 100 ft of nylon coiled hose and enough fittings for 5 hoses _ Today Ships Today UN usos VAUTOMATIONDIRECT 1 Sold by foot price shown for 100 feet Research price buy at www automationdirect com pneumatic parts the 41 value in automation See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved Student Spotlight VAUTOMATIONDIRECT continued from p 26 As part of their course fee the students were provided with all the AutomationDirect Nitra pneumatic parts required for the mechanical apparatus and they enjoyed following along as Scott showed them how to assemble their own barrel pop up When the class was over each attendee had a completed mechanism which needs only an appropriate housing barrel and mask with which to start terrorizing their respective neighborhoods If you d like to see a walk through video of Scott s 2014 Home Haunt visit https youtu be Az7RFj9D8GQ The Barrel Pop up occurs at about 2 30 in this video See if you can spot the other pneumatic mechanisms in the video E 28 Process Sensing from top to bottom TEMPERATURE ProSense family of temper
44. no need to add modules to your base which consume valuable I O slots And there is no need to pay extra for the industry s leading Ethernet protocol EtherNet IP This powerful controller detinitely gives you More bang for the buck The CPU module includes e 2 Ethernet ports that support EtherNet IP Modbus TCP GSDrives auto discover Email FTP programming and troubleshooting 2 Serial ports 1 RS 232 and 1 RS 485 that support Modbus RTU ASCII and even Custom Protocols you define within ladder logic 1 Plug n Play USB programming and monitoring port 4 line by 10 character OLED diagnostic display 50MB of Cc built in memory V LED status indicators Three communications protocols ENS EtherNetZI Removable micro SD slot Up to 32 Gb of data storage per card USB RS 232 RS 485 10 100 Ethernet Multipurpose 10 100 Ethernet Remote I O GS drives only Modbus Automation Notebook Fall 2015 Issue Thirty three In addition to the vast communications capabilities there is a microSD card slot for data logging and project transfer and a high clarity Organic Light Emitting Diode OLED display for diagnostics and simple message display What about Programming o t THTIE HIR 2112 1 i www Productivity2000 com The ProductivitySuite programming software is designed for flexibility and customization Organize the la
45. ow critical benefits of the and non critical fault messages as well as custom messages configured in the ladder using the LCD instruction The analog module displays provide process data and module status at your fingertips a pricey feature from our competitors We give you 4 or 8 channels of raw analog values i e 0 1 OV or 4 20mA converted digital values i e 0 65535 and even actual temperature in deg F or deg C How is TAG NAME programming different from a typical PLC There are two basic types of memory addressing in PLCs today Fixed addressed memory and Tag name database memory www automationnotebook com First would point out that the majority of all controllers designed in the past 15 years are tag name based controllers Since PLCs are designed to be installed and operate for decades without being replaced sometimes progress moves slowly Let s look at how both types function and consider some benefits of Tag based programming 1 Memory allocation Fixed address controllers have a set amount of memory allocated for each data type i e 16 000 In 16 000 Out 4095 integers 4095 floats 512 timers 256 counters etc The down side is they re not adjustable and if you run out of a particular data type you have no additional options lag based addressing is more dynamic You assign data types as you create your tag names You have a maximum amount of memory allocated for that data and it is free
46. proved and value to our popular C more touch Software panels Dozen of new features and For pA9 Series upgrades give you MORE for LESS MORE MATH New math functions let you create custom formulas with constants or tag values The Math Keypad provides both simple and complex operations including log sine and square root MORE ACCESSIBILITY The new Object Layer List Window shows all the objects on the active screen and lets you lock unlock hide unhide objects or quickly select them for editing The Object Layer List allows access to individual objects in a group additional lists for hidden locked or overlapping objects Recipe database supports 99 recipe sheets each with 1000 recipes of 256 possible tags or values operator can now modify and save while the process is active New menu options customizable toolbars and updated graphics for improved ease of use MORE ALARMING OPTIONS Enhanced Alarm List offers more options A for alarm customization New alarm filters allow for dedicated alarm summaries MORE DRIVERS Touch Panels C more panels have drivers for most major js brands of PLCs See the entire list at 499 www automationdirect com c more drivers EA9 T12CL 12 model shown C more EA9 priced at 1790 Software LESS cost 99 5 With software at 99 and hardware EA9 PGMSW starting at just 499 C more gives you one of the best
47. puts and relay outputs for remote control e Built in SCR failure protection and full motor overload protection Get more than you paid for e Two year warranty sg E Ei v 009 www automationdirect com soft starters com 1 800 633 0405 the 1 value in automation Cover Story continued continued from p 8 assurance and quality control software for monitoring and analysis helps achieve this goal Connecting machines to IT or ERP systems allows real time inventory control It also allows remote access by OEMs and their customers These remote access features often use cloud based connections to the IT system Table 1 press an RFID system tracks the cylinders This has eliminated cylinders being lost due to operator error incorrect cylinders being engraved or wrong jobs being loaded n into the engravers continues Gilson in the article The data from the RFID readers also tracks the cylinder carts to make sure the Reasons to Link Machines to IT Systems 1 Optimize operation of each machine 6 Remote access TABLE 1 Reasons to Link Machines to IT Systems Table reprinted from Control Design July 2015 Cover story Tear Down This Wall Open Communication Between the Plant Floor and the IT Network Open communication hardware and software standards make it easier to create and maintain links between machines and IT systems This is particularly true with PC based controls and HMls OP
48. r constructed the 10 x 15 foot structure back in 1949 This quaint chapel is nestled in a small forest of Spanish moss covered Live Oaks to provide a place of rest and inspiration for weary travelers Naysayers said it was foolishness and a waste of funds on such a small structure Maintaining it was the thought that mattered and not the scope she ignored the skeptics and built anyway Some 66 years later people from across the nation continue to stop by to rest reflect and recharge When AutomationDirect began way back in 1993 people said the business model would never work But with determination and proper focus we continue to provide the quality products and award winning customer support our customers expect We have a lot of great material crammed in this issue of NOTEBOOK In addition to information about new products our cover story explains how machine builders and their customers benefit from connecting machines to IT systems Our User Solution story explains how adding a variable frequency drive improved a mill drill machine and our Student Spotlight section is a double feature First students at Penn State have been working on a Baobab pulp processor in conjunction with the residents of villages in Benin Malawi South Africa and also in Madagascar The second spotlight story discusses how Scott Shier exposes a group of fifteen Home Haunter students to the capabilities of pneumatic systems often used in haunted houses
49. s Copyright 2014 AutomationDirect Cumming GA USA All rights reserved Temperature Variable Speed Control Flow Control MEC MENTOR 0 00001 0 C0 04AD 1 CO 04THM 0 040 1 DOAC we on E 020m a amp 20m Koyo mw m E m m m m m Mighty as a stand alone unit or expand to 142 total I O With CLICK PLCs you get a lot of application control in a small package You can replace even just a few relays cost effectively but do a whole lot more with the easy to understand instruction set Gaia An 8 input 6 output base unit with built in serial ports can stand alone starting at just 69 or add any combination of up to 8 discrete and analog I O modules Simple And with FREE programming software we ve made it even easier to give CLICK a try Download the free software so you can see just how simple control can be Configure price and buy at www automationdirect comlclick plc com 1 800 633 0405 the 41 value in automation
50. s users to view download and delete data log files from any browser The 2 69 power supply provides isolated power to the P2000 system bases starting at 69 00 are available in 4 7 11 and 15 slot models any combination of mod ules may be installed in a base without power budget considerations Over 25 modules capture and control a wide range 4 of field signals including up to 16 point DC 16 point and analog voltage current or temperature The OLED interface built into each analog module dis plays field signal levels as well as module and signal faults Hot swappable sup port allows exchange of modules without interrupting the process Each module includes a pull down QR coded tab which can be scanned from any smart phone or tablet to get the latest specifications for that module With the P2 SCM serial communications module 165 the Productivity2000 system can have up to 46 serial ports The module features three RS 232 ports and one RS 485 port utilizing Modbus RTU Master Slave networking ASCII IN OUT and custom protocols port one can also be used to power a C more micro HMI Available specialty modules include two high speed 2 channel counter input and pulse output modules 195 as well as an 8 point input simulator module with eight hand operated switches 47 a filler module 11 for unused slot connections is also available The updated free do
51. simulator P2 O8TRS relay output module 3 different wiring options screw terminal block spring terminal block e ZIPLink pre wired cable and feedthrough connector module USB programming cable Programming software on CD User s manual 16 G microSD memory card Mini torque screw driver 3 wire power cable 30 day FREE Training certificate Everything you need to get started is here http www automationdirect com p2000 hardware starter kit E Productivity 00000000000 ETHERNET microSD USB RS 232 RS 485 Automation Notebook e Fall 2015 Issue Thirty three Just pay once because once is enough 9999999 555555 99999 Competitor PLC 5 2599 9999 555 TONS Productivity 55 V Own it don t owe on it So how much should a PLC cost Does a higher cost indicate greater functionality better quality or does it indicate more overhead more expenses being off loaded to you Buying direct with us saves you money and cuts out the unnecessary costs that are incorporated into each PLC sale you need a PLC then buy PLC not the overhead With Productivity2000 you get many standard features that you would pay thousands for elsewhere Our feature packed P2 550 CPU is priced at 255 and modules start at just 40 P2 08NE3 So ask yourself what exactly are you paying for www Productivity2000 com Renew servic
52. t s newest addition to the Productivity line of industrial controllers The Productivity2000 is a modular rack based system with a full lineup of discrete analog and specialty modules The high performance CPU has 50Mb of user memory fast scan times and five communication ports jor 3299 The P2 550 CPU features a 4 line x 10 character high resolution OLED diagnostic text display with keypad for status configuration system alarms and user defined messages as well as LED status indicators Five onboard communications ports including Ethernet USB and serial support communications protocols including EtherNet IP Modbus and ASCII A micro USB 2 0 type B port provides plug and play connection for programming online monitoring and firmware upgrades One RS232 and one RS485 serial port can communicate via Modbus or ASCII protocols for local networking or custom device interfaces The bottom of the CPU is fitted with two 10 100 Mbps Ethernet ports the first port is used for programming monitoring and firmware upgrades as well as client server connections Modbus TCP EtherNet IP scanner and adapters second Ethernet port is dedicated for up to 16 GST GS2 or DURApulse variable frequency drive connections microSD card slot accepts a standard microSD card to provide up to 32GB of data logging capacity This card can also be used to transfer projects to and from the CPU The CPU s built in Web server allow
53. tion application topics Each chapter starts with a U can do itl overview which explains the capabilities and usefulness of a specific automation task There is a group of Tech Tips vid eos in each chapter where we detail tech nical nuggets and the gotchas that can slow down experts and novices alike when specifying and implementing the topic in question Here s the best part we have How To videos that show step by step demonstrations of exactly how to hook up troubleshoot and even program the task at hand The Cookbook currently includes chapters on Temperature Sensing Object Detection A C Motors On Off Control Distance Measuring and SCADA HMI but check back often for many other automation topics You can navigate directly to www automationdirect com videos cookbook The Automation Cookbook is also easily accessible from any page on the AutomationDirect main Web site Simply click the link Video Tutorials located on the left hand navigation bar marked 1 in the image to the right The Video Home page will be displayed where you can click on the Tab labeled Automation Cookbook 2 The image to the right also illustrates the layout tor each chapter of the cookbook The U can do it video is at the top continued 14 gt gt rect US and 1 Ex Rd WAUTOMATIONDIRECT Direct Sales in US and Canada 1 800 633 0405
54. to easily import this file into C more HMI software Point of View SCADA KepOPC software DataWorx Database software etc If you prefer you can also manually edit the tag database in Excel What aspects of the EtherNet IP protocol are supported by Productivity20002 O Messaging Class 1 implicit Class 3 Explicit Messaging Connected Unconnected Explicit Messaging Both Client and Adapter configurations are supported separately or at the same time The P2 550 CPU is an ODVA certified EtherNet IP device For additional information on EtherNet IP please view our video series https youtu be qqtmmN pnzk What information do receive when scan the QR codes See for yourself Scan the code below Most seasoned engineers or technicians can relate to working on a job site and not having the documentation that you need readily available This is very frustrating and time consuming when working on a system With the new QR codes affixed to 18 all Productivity2000 I O modules you have instant online access to module spec data and wiring diagrams Are there plans for remote expansion for Productivity2000 Yes We will be offering multiple expansion options for the Productivity2000 in the future Are the AutomationDirect GS drives auto discovered in Productivity2000 like they are the Productivity3000 Yes This is a feature that has many benefits Auto discovery saves you time when connecti
55. tomation Notebook Fall 2015 Issue Thirty three _ IMAGE 4 Andrew Mike Erdman and his students help residents of villages in Africa increase production of Baobab fruit powder Excluding the earlier prototypes which were not as functional the students have produced about fourteen machines which are now operating in various African countries Mike estimates that the machines can process a kilo of powder in under three minutes Image 4 That s less than 5 10 of the time required by the manual process and because the mechanical processor only contacts the pulp with stainless steel components the process is much cleaner and the resulting powder is much more pure than is produced by the manual method While Mike admits that the machine is not inexpensive especially by African standards the roughly 1 400 USD cost is largely due to the requirement for the many stainless steel components Even with this IMAGE 5 Penn State Students have 14 machines operating in various parts of Africa expense the increased production volume and purity helps the villagers enormously Image 5 Now they can focus on the other less strenuous but still labor intensive parts of the operation including the gathering of the fruit opening the fruit to remove the pulp bagging the refined powder and shipping to local or export markets B www automationnotebook com VAUTOMATIONDIRECT 111 Om g
56. uld net over a billion dollars per year provided the producing nations can ramp up production and exportation operations Image 1 IMAGE 1 The Baobab tree produces fruit filled with health benefits Grandidier s baobab by Bernard Gagnon is licensed under CC BY SA 3 0 The Baobab tree is known as the tree of life and it produces a fruit about the size of a large coconut with a velvety shell The pulp inside the pods is very high in vitamin C dietary fiber up to 5096 by weight and 20 IMAGE 2 Pulp from the Baobab fruit is eround into powder Baobab fruit by Ton Rulkens is licensed under CC BY SA 2 0 thiamin Image 2 The powdered pulp is added to shakes and used as a sweetener for other fruit drinks and can also be used as a thickener for jams and other foods Processing of the pulp in Africa has historically been done by hand with village women manually crushing the pulp in a large mortar and pestle operation It is an arduous task very slow and not very clean but it is still the most common way produce the powder The engineering students at Penn State set out to help their contacts in Africa with a mechanical means to crush the pulp into powder and to remove the seeds The students are also working on a secondary machine to help process press the seeds into Baobab seed oil for which there is also high demand see sidebar The Penn State Pulp Processor uses an
57. wnloadable ProductivitySuite programming software features tag name based programming for added programming versatility better documentation management and more seamless integration with HMls Productivity2000 gives users the freedom to define user tags with no limits or fixed boundaries With tag name based programming there are no predefined fixed memory maps and no wasted unused memory allocations The software can perform hardware auto discovery and configuration including local base and I O and GS series AC drives The user can also contigure the system offline by dragging and dropping modules After configuration is complete modules can be electronically keyed to prevent incorrect replacement Powerful processes in the programming environment reduce development time time savers include combined ladder logic and function block style programming task management that minimizes scan time advanced instructions that simplify complex tasks and an exhaustive HELP file that covers both hardware and software topics The complete line of Productivity2000 components can be seen at www automationdirect com P2000 Now you can expect more from your HMI MORE Locic New tag combinations allow simple logic with multiple events Combine up to four different tags to E trigger actions based on logical results The C more EA9 HMI software just 99 now delivers more functionality usability Im
58. yout in a way that best satisfies your programming style and preferences Easily auto discover your system and connected GS Drives in the system s hardware configuration Use the tag database import export to manage your tags names or for use with peripheral devices such as OIP HMI and SCADA packages Data View gives you three separate ways to view your process or machine data 1 The simple data view is a table view where you add the tags of your choice view the current data edit or force the data and monitor the Modbus address 2 Graph view lets you drag any tag from the table view and begin plotting those data points on a line graph 3 view offers a unique graphical look at your current physical modules and their data Time for Q amp Does the Productivity2000 support high speed I O modules Yes we have both a high speed input P2 HSI supporting 2 channels up to 1MHz each and a high speed output P2 HSO also with 2 channels up to 1MHz each Both modules sell 195 and both have additional general purpose O Can collect data with the 2 5502 Yes The P2 550 CPU has a microSD card slot built in so recording data from process values is as easy as adding a tag to a list and selecting the frequency at which you would like it to be recorded or define the event that you would like to trigger the process What are the OLED displays The display on the CPU will sh
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