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Automation Notebook Magazine Issue 24, Winter

1. Automaton vote hook WIATEY Lolz Issue Twenty four AutomationDirect and bought a C more Micro Graphic touch panel with a three inch display Using the PLC and the touchscreen he found he could now exceed the original capabilities of the machine for less money than it would cost to restore the original functionality The original mechanical predeter mining counter had a maximum count of 99 999 It would count every stroke and would stop at the preset which had to be a value less than or equal to 99 999 This reduced the efficiency of operation as its not unusual to have jobs of 120 000 to 300 000 copies With the CLICK PLC and the touch screen the machine is now capable of counting to 9 999 999 Dobiesz also added a counter stop switch that enables the machine to operate without advancing the count as well as a counter bypass switch that enables the machine to continue to operate in excess of its predetermined count New Functionality Added with Ease Thanks to the large amount of pro gram memory space in both in the PLC and the touchscreen Dobiesz was able to add needed functionality via screens counters timers and more all at no additional hardware or software cost As long as I have inputs and out puts for connections my imagination is the only limit to what I can do If adding additional software programma ble switches time delays or control relays add needed functionality I just update t
2. Cut Resistant Sleeves Puncture Impact Cut Resistant Gloves 29 50 pr TTP455 Series Cut Resistant Gloves 7 00 pr TTP050 Series with polyurethane palm In stock to ship same day and free shipping on e Safety Glasses orders over 49 starting at 2 75 SG 754 e Safety Light Curtains Relays and Switches VWAUTOMATIONDIRECT the 1 value in automation ee our Web site for detalls and restrictions Copyright 2017 Autemationfirect Cumming GA USA All ights reserved Cover Story REdale Ort Ating o0s7s WAUTOMATIONDIRECT Reducing Total Cost of Ownership By Christine Lesher Automation is a key component when developing strategies to help customers reduce their operating costs se any times when making buying decisions people look only at the initial price of an item without considering other factors that contribute to the overall cost of owning that product For example a certain laptop may seem like a great deal before adding the cost of the operating system and the software and the extra memory needed to augment the unit Moreover the low initial price might mask the fact that the cheap laptop will become obsolete much faster than a more expensive unit or that it may not be robust enough to withstand the rigors of travel This example is similar to purchas ing decisions that must be made when buying an industrial machine In addition to the
3. Master modules PWR RUM ROM ERR H2 DM1E installed in the local base can each connect to up to utomationDirect has released the latest addition to its PLC offerings the Do more H2 Series PLC This new PLC line offers features and performance of high end PLCs for an economical price Using the proven DirectLOGIC DL205 hardware as a platform the Do more H2 PLC supports all base units discrete and analog I O modules available for the DL205 PLC However it has a much more flexible and advanced design that makes integrating I O and organizing a program much easier The H2 CPUs offer four times more program memory nine times more data memory and operate at speeds up to 20 times faster than current 4 16 remote I O subsystems which can provide hun dreds of additional I O points H2 CPUs system cost and series reduce space by including embedded communications ports The H2 DM1 CPU with one serial and one USB port sells for 299 the H2 DM1E also includes an embedded Ethernet port for just 399 Device abstraction makes it easy to connect external devices EF T H E R N E Ta by allowing the user to assign logical names and then refer to those names throughout the program code for ease and clarity Programmed using Do more Designer software that can be download free of charge the Do more PLC provides an advanced instruction set to reduce programming time superior memory mappi
4. 5 Speed limits The engine has to stay within 95 105 while running in steady state Application With the engine fully automated it can be used in an automotive applica tion and use the shaft power coming from the planetary gearbox at 6 000 RPM The plan is to run the engine at constant speed and use a continuously variable transmission CVT to transfer power to the wheels The CVT primary would be adjusted possibly hydraulically by the car foot pedal throttle to vary output power Continued p 33 gt gt R R I f f 44 i _ TITTLE It could cost you a lot more in the long run But you don t need to overpay to get reliable high performance safety devices that conform to all the latest standards Our prices on safety relays switches and light curtains mean you can do even more to protect what s important Safety relays are coils and contacts that are designed to be positively driven and assure a reliable opening and closing for machine safety applications Dold safety relay modules are developed and manufactured according to IEC and EN European standards and are RoHS CE and UL Listed e Emergency Stop Relays Gate Safety Relays e Time Delay Safety Relays e Two Hand Safety Control Relays NEW BH5932 series soeed monitoring safety relay modules use proximity sensor inputs to determine motor rotation speed and provide standstill and overspeed monitoring of m
5. Design for TCO article January 2012 Flexible Manufacturing Although the features and functionality of automation technologies have been increasing significantly their prices have remained relatively constant This is good news for OEMs because the relative cost of automation actually is getting smaller often includes structural steel motors sensors robots conveyors and other systems The Control Design story takes a look at how Industrial Technology Solutions ITS a system integrator in Ohio money by updating older control Columbus saves customers FREARRKRKKRAKRKRRF I m J o sie 9 P 9 9 9 Automaton vote Look WIAVTEr zoz Issue Twenty four systems Figure 3 on page 14 Design engineer Brian Engle says If the equipment is not functional then the manufacturer isn t making money He adds The advanced diagnostics and interfaces that automation can provide are in my opinion the best use of automation for an end user See page 14 for more details on this ITS application visit Web site at www industrialtechnologysolutions com for other applications Outdated controls operating costs due to their inadequate higher maintenance costs and shutdowns that often raise operating efficiency affect production For example an OEM recently discovered the benefits of adding a motion controller to reduce costs In this case a plant used some high
6. E nia p l r i i n A i a7 A i 5 Be ir j r r j f i abi i ai d r g l i i i i p i iy Brae l P T A 7 ivy WVW VW E5 j LF Ol i ql F H Wwe POP Os he Re OP E B 7 e E hi al A i i w F S tnt ka Li E wr i i wea YAUTOMATIONDIRECTE hoi a me http bit ly p3000 PERFORMANCE VALUE PRODUCTIVITY Aa Copyright 2012 AutomationDirect Cumming GA USA All rights reserved
7. F 1 3 iE i es AM aN 550 CPU iL we rmm esai R MA ser Ay ENTI ADi LT P3 J2HDJ a oe PISTR jearjg Category Winner a rr WAUTOMATIONDIRECT 1 P30IAC www productivity3000 com boosters Easy DAQ or SCADA with low cost 1 0 and practical software Use the technology built into the Productivity3000 programmable controller to make your job easier If you need data collection from the factory floor lab or field it s a system worth looking at Speed and power y y J Flexible design Integrated O Communications One program instruction in the controller connects and passes data to all the common database formats Microsoft Access ODBC and SQL Server Low cost server software DataWorx P3K starting a Powerful at 595 makes the data readily available to your upstream appli ee cation Advanced instructions The FREE Productivity Suite programming software comes with HELP when you a trial version of DataWorx P3K so you can experiment with need it and test your database application with no risk Extreme HMI l l Helpful For simple data logging the CPU can write data to a removable diagnostics mass storage device USB on an event or time basis Data exchange Read more watch free videos and download the FREE software at g F 3 E h a Fh F n m mp a am ii gs e
8. The configuration tells H2 CTRIO2 whether to encoders or discrete devices such as the expect limit switches or proximity sensors on its inputs it also defines whether to use outputs fora stepper as slaves to a PLS or Preset Table or as discretes accessible by the ladder program it can also define preset tables or PLS tables or configure timers Easily step through a sequence of moves using Stage programming To easily command a sequence of moves all the motion instructions now include Stage control Since Stage programming works well for sequential tend to be processes and moves FRARARKRRKRKAKF eo Sebebeeeee Automaton vote Look WINTE zoz Issue Twenty four sequential the motion instructions can make stage transitions as they complete As a result some programs to control motion can be surprisingly short Integrated Programmable Limit Switch To improve upon the precise output control offered by Preset Tables in the H2 CTRIO the H2 CTRIO2 adds integrated Programmable Limit Switch PLS functionality Where events in the Preset Tables had to occur ina specific sequence events in a PLS occur based solely on the input counts Furthermore PLS entries and Preset Table entries can be added edited or deleted using several new intuitive ladder instructions in the Do more CPUs More easily set up the machine using Axis mode jog To simplify machine setup the JOG command makes manual
9. based programming software for PLCs and has served its purpose well over many years However the engineers at Host had a dream to develop a completely new control engine that could take advantage of current technology The Do more PLC is their accomplishment We named it Do more To tell the truth it was not an easy job for us to come up with a name The the beginning and we came up with more naming process was fun in than 100 possible names However it eventually became a daunting job some people like a name and of course others don t In the end we came up with this simple name that conveys a message Do more is what you can expect with this new PLC Do more Designer I have been using the programming daily during the development and through the release And as the DirectLOGIC product manager I also use DirectSOFT almost daily I have to admit I feel more comfortable using software Do more Designer Do more Designer This is because of features that help the processes of 16 creating editing and troubleshooting the ladder program such as the Project Browser and the Trend View The software Help file covers all the infor mation you need to write your program I refer to the Do more PLC user manual only when I need to set up the jumper switches in the analog I O modules or wire the H2 CTRIO 2 modules If you spend some time with Do more Designer youll see what I mean Do more instruc
10. controls which means that the fuel scheduling is based on mechanical inputs The fuel control pump is gear driven and fuel is scheduled based on engine speed and compressor pressure In addition to maintain constant engine speed as a function of varying load a governor watches engine speed frequency and outputs voltage to the torque control motor i e throttle which is also connected to the fuel controller The team modified the engine controls by using a DirectLOGIC DO0 05DR D PLC with an F0O 04AD 2 analog input module and a six inch C more model EA7 T6C touchscreen HMI display The PLC controls the start sequence by engaging and disengaging accessories as a function of engine speed while the input module monitors how well the engine starts and continues running different parameters are used for each To keep the engine running at 2 000 Hz 100 speed a commercial diesel engine governor is used to schedule the fuel to the engine via a fuel torque control motor The PLC s analog input card requires signals in the 0 10V range Appropriate signal conditioning was used to convert engine speed and thermocouple readings into the appropriate voltage ranges The team initially faced some challenges getting accurate speed readings at all engine speeds which determines when the PLC actuates accessories because the signal pulse changed shape and amplitude This was easily solved with a single resistor A view of the co
11. IPM LED status indicators two PNP sensor inputs and two normally open and one normally closed positive guided contacts Available for 24VDC 120VAC and 230VAC supply voltages prices start at 279 The LH5946 standstill monitor relay module provides safe standstill detection on single phase and three phase motors up to 690V by monitor ing remanence voltage without external sensors The monitor relay modules are designed with broken wire detection and provide three normally open and one normally closed positive guided safety contacts Available in adjustable 20 to 400mV and 0 2 to 4V voltage response ranges standstill monitor relay modules are equipped with LED status indicators and adjustable time delay semiconductor outputs monitor relay state Available for 24VDC 120VAC and 230VAC supply voltages prices start at 349 Safety speed relay modules are cULus CE and RoHS approved and are backed with a one year warranty For more information visit www automationdirect com safety speed relay FRARKRKKKF l FRARRKKKARRF TIA Automaton wore Look WINTEL zoz Tssye Twenty four Solve noisy signal issues with high speed optical isolators i a ata WW am Eoy Hat Th p at e _ Ji E yi tel ee Paa i i a PE Ea AutomationDirect offers high speed optical isolators providing the versatility to solve various interface now problems between an incr
12. Most of a machines operating costs come from its energy usage making energy efficiency an selling point OEMs are responding by building more energy efficient machines In order important to improve they need to see exactly how energy is being used by their machines Monitoring energy consumption can provide the knowledge as to where improvements can most easily be made In the Control Design January 2012 story Design for TCO Carl Henning deputy director of PI North America www us profibus com explains an approach to uncovering energy costs by using Profienergy a function of Profinet Henning says One of the features of Profienergy is the ability to format data into useful information about energy demand This information can be used to avoid demand peaks Extending a Machine s Lifespan Monitoring also provides valuable information beyond energy usage that may help machine builders provide better TCO for their customers such as how to extend the life of a machine by protecting it from damage Embedded monitor motor currents vibration and intelligent devices torque signatures which help machine builders with protective these problems By protecting against the machines design functions against damaging effects of electrical and other hazards they can provide long term equipment protection that extends the machine s life and reduces the frequency of equipment replacement Looking at Hib
13. adjustments to position very simple And to complement the new PLS functionality two ladder instructions assist in dynamically editing any PLS from the ladder program If a PLS will always be dynamic simply create a blank PLS in the configuration and push values to it from a table in your program as it executes Summary We continually strive to improve our products and value your opinion For additional information on these features and more and to download the free Do more Designer software which introduces a powerful intuitive set of programming tools visit the Do more PLC Web site at www domoreplcs com S Edit CTRIO CTRIO Configuration hiFni Ee Mame creo 000 CIF ChijFn2 Name CnuOFneeEnc aar faa Name CTO poi C22 Chafni Sa Input Filters Ohi A 1000 ns Chi 1000 ns chic Wons aA 00n ZB 00n CHE ioon This H2 CTRIO2 Module Configuration summary page shows four channels configured to accept signals from two quadrature encoders two output channels configured to control a stepper motor and two other output channels configured to activate based on PLS table events referenced to the quadrature encoders An archaeologist is the best husband a woman can have The older she gets the more interested he is in her Agatha Christie You are never too old to set another goal or to dream a new dream C S Lewis He that would live in p
14. and spring back Engle shoe to compensate for explains A linear cable position encoder allows the bending shoe to measure pressure or positioning sensing The new HMI is an integral part of the process as the gateway for the operators to interface with the PLC Maximum product output is now achieved as a result of the system s that optimize advanced diagnostics shorten and procedures The manufacturer can downtime setup measure the improvement in TCO directly in terms of reduced scrap Figure 3 ITS was able to modernize this horizontal bender machine using solutions from AutomationDirect including the PLC HMI and sensors as well as steppers and servo controllers for coordinated motion 14 quicker turnaround on custom Jobs and reduced labor for setup and operation ITS understands the goal of automation is to make work easier for the user Troubleshooting a machine can be a daunting task for most plant personnel We try not to overcomplicate that process with sophistication When the situation unnecessary demands it a more complex control system can be implemented and easily justified by its advanced diagnostics and intuitive interfacing techniques on ec e e e e e 9 EA TGCL A C more touch panels in 6 to 15 sizes are a practical way to give plant personnel easy access to controls and data Check out the powerful yet easy t
15. at Arpac www arpac com maker of packaging equipment in Schiller Park Ill says Automation is a key ingredient in providing the flexibility that customers demand in our type of equipment He adds Modern industrial controls allow us to produce core machine designs that we re able to customize to fit a wide range of applications Figure 2 unlike mechanical components such as gears and linkages Therefore automa tion technology improvements are good ways for OEMs keep their costs down while delivering better products to their customers The ability to develop more flexible designs is a good example of how automation helps improve TCO For example if an infeed can be modified through automation to be flexible to accommodate a 12 or 16 inch opening this can become a standard single product rather than having a 12 in machine design and a 16 in machine design explains Michael Gurney principal at system integrator Concept Systems www conceptsystemsinc com in the Control Design story Reducing TCO in Existing Machines How can TCO be lowered for existing machines in service Upgrading the control system is one of the best ways to reduce TCO on an existing machine It eliminates the need to replace expensive machinery which Figure 2 This ARBOT machine is an automated robotic palletizer and stretch wrapper built by Arpac Automation provides the flexibility required to cut TCO Courtesy of Control Design s
16. inch STN models also available e Analog touch screen for maximum flexibility e Easy to use software 2012 CHOICE AWARDS WINNER e All AutomationDirect PLCs PACs e Allen Bradley ControlLogix CompactLogix MicroLogix 1100 1400 Ethernet ENI Adapter for SLC Series FlexLogix SLC 5 05 Ethernet MicroLogix e Modbus RTU and TCP IP Ethernet e GESNPX e Omron Host Link Adapter C200 C500 FINS Serial and Ethernet e Selected Mitsubishi FX Series Q Series e Siemens S7 200 PPI and S7 200 300 Ethernet ISO over TCP IP 15 inch TFT inch TET 10 inch TFT 540 Software and firmware are downloadable for authorized customers from VAUTOMATIONDIRECT the 1 value in automation Product Management Comer WAAT i5 A Do more PLC WAUTOMATIONDIRECT By Sammy Natsui PLC Product Manager AutomationDirect t 9 14AM on September 6 2012 released PLC Many customers already knew AutomationDirect the new Do more that Host Engineering the developer of the Do more PLC had been working on this next generation CPU for several years Here are some observations from a personal perspective What is Do more If you have ever used a DirectLOGIC PLC you probably know Host Engineering they developed the programming software DirectSOFT and also specialty modules such as the Ethernet communication modules and the high speed I O modules DirectSOFT was the first Windows
17. is more than just its purchase price Using a customer s own numbers instead of a general estimate to show how the machine can reduce labor or maintenance costs helps them to better visualize potential savings www automationnotebook com Engle from ITS explains how using a customer s own data is more effective than simply giving them general figures If a company tracks maintenance and equipment downtime it s fairly simple to show payback he says Most manufacturers feel comfortable with numbers coming off the equipment and can schedule accordingly They demand a solution that will provide them the ability to minimize production loss and maximize profit This can be proven to do so through their own collected data Lastly its important to note that not every customer needs every feature Automation technology is a big factor in reducing TCO but most clients don t need all the latest technologies OEMs must determine which features and technologies will help their customers achieve their goals and eliminate superfluous features This doesnt just help to close the sale it also helps customers achieve their specific goals increasing the likelihood of repeat business S 13 Cover Story cont WAUTOMATIONDIRECT RELE Or Aing losts Making Processes and Automation Easier here are times when a perfectly good machine is replaced when the better alternative would be to simply replace the cont
18. of boards that may be either 1 2 or 3 feet shorter than the eight longest Can you determine the lengths of the 16 boards 3 Play Floor Square Two square rooms are to be tiled with 1 foot square tiles The total square footage of both rooms is 2120 sq ft One of the rooms is 12 feet larger on each sidess than the other Can you determine the dimensions of the two rooms People everywhere confuse what they read in newspapers with news A J Liebling Please visit www automationnotebook com to find the answers to these puzzles KRKKKRKKRKKKKKKKRH managed Models ar a9 Or 199 oO a Penclioct irrenges mot bo srake a Models Unma go AN fg Ra 99 00 ws Lal p ES p lal i mi Ly SE FW5U An mga fee Fade sA r i zi i a 4 Comore Touch Panel DLOS Micro PLC err s PLE ticro Our STRIDE family of industrial grade Ethernet switches and media converter is specifically built for industrial environments Install Stride switches and your Ethernet control network will maintain more consistent cycle times even under heavy I O and data exchange Our new managed switches offer fast Ethernet and Gigabit options as well as fiber SFP transceiver modules for select units Managed switches offer security redundancy and enhanced traffic filtering CHECKOUT PRICES ON ETHERNET SWITCHES AutomationDirect Price Part Number 5 port unmanaged Ethernet switch with 99
19. or a cam driven mechanism In this scenario costs are likely to increase rather than decrease On the other hand if a new design is optimized to take advantage of the functionality offered by the servos the costs are diminished Another great way to reduce unscheduled and maintenance costs is by upgrading from even required older technologies like line shafts pneumatics or chain drives to servos and steppers We re upgrading a seed packaging machine from a chain drive system with interconnected timing gears and belts to a completely modular design using independent steppers and controllers from AutomationDirect for Servo coordinated motion Engle of ITS says The existing system is extremely difficult to adjust as one adjustment leads to every other aspect of the process running at a different speed Changing to steppers and servos will eliminate the problem Educating Customers As mentioned in the beginning of the article too many buyers only look at the initial purchase price not all the extra costs that can turn a bargain into a money drain Educating customers about how the initial extra cost from new technologies can help them save money over the lifetime of the machine can be a challenge for OEMs The first steps are to understand each customer s needs and to then find the right solution for that customer OEMs need to take the time to help the customer recognize how the total cost of a certain machine
20. programmed to run repetitive cycles that turn units on for an hour then off for 15 minutes for example We log the monitored temperature data in Excel with communications between each PLC and our three PCs via KEPDirect OPC software OPC communications provides us with an easy way to transfer data using standard protocols We quickly learned how to use the OPC DDE server to collect data and to write or modify macros in Excel to graph the collected data Daily graphs show dips in the oven temperatures if there are issues or failures This functionality allows us to run our tests continually reducing total project testing time 22 We use RS 232 or Ethernet for these PLC PC connections We use four industrial PCs and three laptop PCs in the cooking and refrigeration test lab to log test data and to write test programs and profiles that run on the PLCs We also use these PCs as HMIs We use DirectSOFT5 Windows based PLC programming software to write or modify the test programs used to test appliances or component parts For example we recently created a program that tests three gas ranges in bake mode The program repeatedly turns the ranges on for 30 minutes and off for 10 minutes Results Verify Expected Benefits We ve found the Automation Direct PLCs to be simple to use affordable flexible and highly reliable Without much in the way of prior experience we were able to learn how to program the PLCs in ladder logic pro
21. ser MOVE Figure 1 Instruction Palette Spend less Do more Have you watched the overview video of the Do more PLC The link is available at www do moreplcs com Because the Do more PLC has more features and better performance in comparison to the current DL205 MWX PLC for applications that you Do more have never been able to do with our other PLC products because of missing features and or performance With this new PLC you will find you can Do more FRRRKRKKRKRRF ao 9 e 9 PNEUMATICS is Parts you use every day at everyday great prices We ve got the pneumatic parts you need and they ship the same day New air pilot valves are a basic component of many pneumatic systems our AVS 5 series can be used individually or multiple valves can be assembled on manifolds available in up to 8 stations Manual control valves are designed for non electrical operator control applications These basic valves are available in toggle hand lever push pull and rotary hand lever styles as well as foot pedal valves See everything at Pneumatic Air Cylinders Mig os Fittings and a ba Air Couplings 4 t d pa Pneumatic Solenoid Valves and Manifolds jee gur Wieb sie tor detai and PSCC ON O Domyright 2012 AutomatoniHrect Cumming GA USA AN rights reserved Ags wring DHe Taes EL L a i start at 14 00 Bod
22. speed valves that cycled often and the cushions that the valves sealed against would often wear out requiring the whole plant to be shut down while the cushions were replaced A motion controller was added to properly accelerate and decelerate the valves at high speed without causing impact of the valve seat at the end of stroke This relatively simple step helped the plant eliminate the three shutdowns per year that occurred prior to the upgrade resulting in measurable and significant cost savings and reduction in TCO Rethinking Mechanical Line Shafts In addition to control systems mechanical line shafts are also good candidates for upgrades in order to reduce TCO One company found that replacing mechanical line shafts with individual servos greatly minimized the setup time of a machine Its client had a food processing machine for which each product change required up to half a day just to tweak mechanical cams of a line shaft to ensure proper timing of the machine By replacing the mechanical line shaft and cams with individual servos the timing is now stored as a product recipe its simply recalled with the press of a button on the HMI for a product change The increased production flexibility and reduced downtime for the customer quickly achieved payback for the slightly higher initial hardware cost However caution must be taken when using servos as replacements especially if a design is optimized for a pneumatic
23. starting at 6 75 pair can be found at www automationdirect com work gloves Cut resistant protective sleeves are available in single and dual layer styles The ambidextrous design features a tube knit with integrated knit wrist and thumbhole Starting at 10 for a single 18 inch sleeve more information is available at www automationdirect com protective sleeves Dual rod guided pneumatic air cylinders The NITRA pneumatic product line now includes E Series dual rod ideal for require cylinders that precise alignment or have large side loads NITRA E series dual rod guided pneumatic air cylinders are interchange able with other popular brands of cylinders The double acting cylinders guided air applications are constructed with high quality extruded aluminum housing and switch mounting tracks dual chrome plated Continued p 8 gt gt 7 Product Snapshots cont Press Releases WAUTOMATIONDIRECT Continued from p 7 stainless steel guide rods and bronze bushings E Series cylinders feature a maximum operating pressure of 142 psi and are available in eight bore sizes from 12mm to 63mm depending on bore size available stroke lengths range from 10mm to 250mm Prices for NITRA E series dual rod guided air cylinders start at 94 The complete line of NITRA E series seen at cylinders can be www automationdirect com guided air cylinders To see the full line of N
24. up to 250 kHz All configuration and profile setup functions are built into the Do more Designer software to integrate the module with the application logic Two available starter kits provide a prewired 3 slot base with choice of Do more CPU an 8 point input simulator module and an 8 point relay output module Also included are a copy of the Do more Designer software on CD a hard copy of the user manual a USB programming cable and a coupon for free online training Starter kits start at 536 For more information please visit www automationdirect com do more plcs FRARRKKKRRARRKF TITE z9 9 9 9 PHR Ri ROM ER H2 DM1E a att i D2 068 1 11022060 e More program memory e More and flexible data type memory e Faster program execution e Easier to use instruction set e Integrated Ethernet on the CPU e Faster I O for counting and motion applications e More and easier to use communications The new Do more H2 series CPUs leverage the existing line of DL205 I O modules and base units to create an incredibly powerful PLC at an incredible bargain Two CPU options are available H2 DM1E H2 DM1E 1 USB port for programming Fa oa aA 1 full duplex serial port 1 Ethernet port H2 DM1 1 USB port for programming 1 full duplex serial port e Over 1M bytes total memory includes program data and documentation e Program monitor debug over any
25. 00 e Unmanaged switches offer up to 9 ports in plastic or metal housings 5 10 100BasE T R143 Erhernetports 99 0 e Managed switches in metal cases support up to 16 ports Sporuna ern 1 74 00 8 10 100BaseT RJ45 Ethernet ports 5 e All RJ45 ports are auto detecting auto crossover and auto polarity SE SWBU e Redundant power inputs with surge and spike protection Spon managed Ethernet switch with 445 00 g z sae 5 10 100BaseT RJ45 Ethernet ports z e SC push pull type fiber optic connector models in addition to ST SE SW5M slotted bayonet style versions 8 port d Ethernet switch with 8 Gigabit l eee Sort managed Ethemet swich win sigt 1 290 00 e SFP transceiver modules with LC fiber connectors available SE SWEMG 4P 16 port managed Ethernet switch with 1 1 50 00 16 10 100BaseT RJ45 Ethernet ports SE SWI6M i e Store and forward wire speed switching no delays e Full duplex operation with flow control no collisions ee e Auto crossover MDI MDIX and auto polarity e Ethernet Isolation 1500 VRMS 1 minute e Wide operating temperature ranges e UL CUL listed and CE certified e Hazardous locations rated for Class 1 Div 2 Shielded Cat5e cables starting at 5 00 VAUTOMATIONDIRECT See oar Website for detai and restrictions Copyright 2012 AutomationDinect Cumming GA USA All rights reserved th e 1 Va ue l n a utom ati O n TECHNOLOGY THAT MAKES YOUR JOB EASIER i fa pa 00 i A
26. 2 from the beginning to work in concert the overall experience is vastly improved especially writing the application program 26 Basics of Do more with H2 CTRIO2 New hardware the previous CTRIO but the specs aren t outperforms the biggest change Comparing the specifications of the H2 CTRIO2 to its predecessor shows some obvious improvements but only begins to tell the story The H2 CTRIO2 inputs are 2 5 times faster and the outputs are 10 times faster at 250kHz and 250kHz respectively However the most significant changes arent in the specs they re in how this unit works with Do more to simplify and expand motion control capabilities The loaded with features H2 CTRIO2 module is which help simplify motion control such as axis mode instructions Axis Mode To greatly simplify tying ladder logic to the desired motion the new Axis Mode instructions were designed to provide an intuitive interface for from the commanding moves H2 CTRIO2 After configuring the I O of the module you drop in a CTAXCFG Axis Mode Configuration ladder instruction to define the limits of maximum speed start speed acceleration and decelera tion rates Optionally you can pick an encoder to use for feedback and configure it Once an output is in Axis Mode use any of the Axis Mode instructions to control the stepper CTAXLIMT Axis Mode Limit to home the axis CTAXJOG Axis Mode Jog to manually jog CTAXTRAP to mak
27. A All nights reserved Great unit for for the cost Ideal unit for those smaller projects FRRRKKF RPh RR l Tee IEF Engine llah Automaton wore Look Winter zoz Issue Twenty four Student Spotlight Cont Continued from p 30 Part II Tiernay I 10 FADEC Engine The team is also automating a second gas turbine a Tiernay TT10 Like the Solar T62T 32A this turbine was also taken from a military auxiliary power unit APU The engine runs at 50 300 RPM and through a planetary gearbox reduces to a 12 000 RPM shaft output speed used to run a DC generator which yields 28V DC 10kW for starting and running aircraft on the ground controller would start the engine with a constant output PWM to the fuel pump Once 50 speed is achieved the output transitions to a PID loop where PWM output is varied as required A screen shot of four of the parameters recorded during data logging is shown in Figure 6 For this engine the team chose the DirectLOGIC DLO6 model D0 06DR D PLC with the FO 04AD 2 analog input module and the 8 inch C more model EA7 T8C touchscreen HMI to run the engine at Figure 5 Tiernay TT10 A view of this gas turbine in our intended application a shifter kart is shown in Figure 5 This gas turbine is different from the Solar in that it is run by a Full Authority Digital Electronic Controller FADEC which means the engine fol
28. Automatic recording of test data was another goal as this would allow analysis and improvement of test procedures Finally better test data would enable us to improve our product designs To reach these goals we began using PLCs for reliability test stands An electronics engineer working on dishwasher products suggested using DirecttLOGIC DLOG PLCs from Automation Direct We found that the AutomationDirect PLCs were simple to use economical to purchase and that they could measure everything we needed to test the dishwasher components When the time came to build more test stands as well as start the cooking and refrigeration lab we turned to Automation Direct We continue to use AutomationDirect DLO5 and DLO06 PLCs in our test labs We use both AC input and DC input versions of both PLC models Other modules we use include thermocouple input and 0 10 VDC analog input We typically don t use analog or solid state outputs but use relay outputs instead Other AutomationDirect products we use include C more 3 inch Micro Graphic touch panel HMIs DirectSOFT5 PLC programming software and KEPDirect OPC software Washing our Hands of Manual Test In 2003 the design of a new dishwasher product started Viking range on an evolutionary path toward creating reliability test labs and using PLCs to automate test stand operation Figure 1 Automated testing of products like this range enables Viking Range to provide high q
29. CT the 1 value in automation Product Snapshots Press Releases WAUTOMATIONDIRECT lronHorse stainless steel general purpose AC motors The IronHorse general purpose AC motor line now includes stainless steel three phase motors available in horsepower ranges from 0 33 to 2 hp Motors are available in speeds of 1800 and 3600 RPM and are electrically reversible The three phase industrial duty 56C frame TEFC motors priced from 275 feature 304 stainless steel frames and stainless steel shafts IP56 rated they are equipped with a large easy to wire junction box with fluorinated silicone rubber gasket and stainless steel cable gland These NEMA design B motors are available with or without mounting feet and can be mounted in any orientation horizontal or vertical as long as the drain plugs are installed in the two lower locations The stainless steel series is CSA certified and is designed for washdown applications as well as being ideal for applications such as conveyors fans reducers and pumps The new IronHorse stainless steel gear motors are available for same day shipping and are backed by a one year warranty View the IronHorse stainless 6 steel motors at www automationdirect com stainless ac motors More ultrasonic sensor choices Our line of ultrasonic proximity sensors now includes additional 18mm round plastic DC models The UK1 series are P67 rated sensors wit
30. Cs more easily and for much EAT S3MUN Cine sid effort less money See what our customers are saying much better alternative to the other pico type controllers This is a great product for someone that has never used a PLC before As far as bang for the buck value this is the best PLC With CLICK PLCs you get a lot of application control in a small we have found package You can replace even just a few relays cost effectively but do a whole lot more with the easy to understand instruction set Try it out if you don t like it use our 30 day money back guarantee CHECK OUT JUST A FEW PRICES ON CLICK Aut tionDirect e Eleven stand alone DIN rail mountable mS DC powered CPU combinations including PLC CPU with 8 DC inputs 6 DC outputs sinking 69 00 E two communication ports cCo 00DD1 D PLC CPU with 4 DC inputs 4 DC outputs sinking 2analog inputs 2 analog outputs three communication ports 129 00 real time clock C0 02DD1 D Auxil ly 0 5A 100 240 VAC n _ AUDE OBmoupue OSA me eg Built in communication ports AC input module eight 100 120 VAC points 540 00 e Battery backed memory and real time clock CODENA e Removable terminal blocks for easy wiring e Program AND documentation stored in CPU Ty fi S Or AUTOMATIONDIRECT the 1 value in automation See our Web ute for details and restrictions Copyright 2012 AutomationDirect Cumming GA US
31. ITRA pneumatic cylinder products go to www automationdirect com air cylinders ProSense line now includes room temperature sensors and Type T thermocouples AutomationDirect s ProSense line of temperature sensors now includes room temperature sensors Type T thermocouple probes higher range probes Type T thermocouple wire and RTD adjustable immersion sensors The ProSense room temperature sensors feature a temperature sensing range of 40 to 185 degrees E are constructed with ABS plastic ventilated covers metal wall mounting subplates and an internal terminal strip for wiring connections The ambient temperature sensors can be mounted horizontally or vertically and are available in Type J thermocouple and Pt100 type RTD versions prices start at 25 Type T thermocouples starting at 17 23 added for have been 8 applications lower temperature measurement Available in requiring attached plug and heavy duty lead wire models and in six 12 and 18 inch probe lengths the 1 8 inch diameter probes feature a temperature sensing range of 328 to 700 degrees F Type T thermocouple extension wire is now available in 50 100 and 200 foot lengths starting at 15 75 Additional Type K thermocouple probes with higher measurement are now available Fitted with Inconel Alloy 600 sheaths to protect against harsh environments the temperature probes are available in six 12 and 18 inch lengths quarter inc
32. Your guide T0 O LL ACTICAL Pr oducts 1eci An0109 S and A2QAICAT fons Automation NOTEBO WINTE 202 h Cover Stony g i iRed ucing Total Cos of Owners hil Ip Py 22 a a 7 i AR Feature Story Bringing Life to an Old Machine New Product Focus AutomationDirect launches new Do more PLC and Counter Module PEPTIDE User Solutions PLCs Automate Reliability Testing 3 R Technology Brief Ease of Motion with Do more PLC and the H2 CTRIO2 rk i f eI feos plus FREE Windows based configuration software moe micro We squeezed the features of our popular TFT 6 inch C more Micro into a 4 inch package for even more value Take advantage of the clear and colorful graphics on the TFT color touch screen to create a vibrant and intuitive operator interface Five programmable function keys Get a big bang for your buck give you lots of flexibility FREE programming software offers the Oot Hl stag ar a OMe ator choice of using many built in objects such as buttons bar graphs and ik LA touch shee ey acklight data entry keypads Or import your own custom graphics and save to libraries for use in multiple projects Alarm control recipes and a built in project simulator are time saving tools for more complex applications All these features at a competitive price in a rugged and VAEV UNBE tuinetion keys WHI LED inbicakars reliable package give you a sweet HMI for even the smal
33. and then Tennessee made early Viking Range products all production moved in house to our Greenwood Miss facility in 1990 In house manufacturing enabled our company to provide higher quality and greater reliability but we wanted to improve further and saw automated testing as a means to that end Figure 1 Why Automate Product Testing The dishwasher lab and the cooking and refrigeration lab are our two main reliability test labs We started the dishwasher lab in 2003 and the cooking and refrigeration reliability lab in late 2005 Before we created the labs product engineering did their own testing At that time product engineers weren t 20 Why Automate Product Tests 1 Standardizes test procedures 2 Facilities compliance with industry standards 3 Cuts test time 4 Reduces labor requirements 5 Automatically records test data 6 Allows analysis and improvement of test procedures 7 Enables improved product design Table 1 Reasons to automate product tests using PLCs and testing products manually was burdensome so we needed to build several automated test stands for testing components to be used in dishwasher designs By automating the test labs we aimed to reach several goals as outlined in Table 1 We needed to standardize test procedures to facilitate compliance with industry standards and to improve product testing in general We wanted to cut test time and to reduce labor requirements
34. are concept into the DL 205 PLC and 830 Eldorado Avenue adjusting in real time as the speeds and Huntsville AL 35802 a tensions of the yarn strands changed T How did you overcome the obstacles The obstacle of getting a concept to a pattern and then into the PLC as a series of actions was accomplished through Net programming This ability to program at multiple levels PC PLC is one of the advantages offered by KCC Software The timing issues related to adjusting the spray application based on real time tension and speed p fluctuations was accomplished through a central timing algorithm that drove the dye application Both major obstacles were overcome through well designed algorithms Maples Rugs high speed dye application monitoring screen Tell about a breakthrough moment for you in your approach to control system applications Prior to 2000 all of my programming was in C and in both embedded and PC based applications Around 2001 I saw a PLCDirect catalog with a new DLOG PLC on the cover Be a yardstick of quality Some people aren t used to an environment where excellence is expected I immediately saw how combining PC based programming with the PLC integration would help me provide better and more robust solutions for my Steve Jobs clients The low cost yet powerful and capable entry into the PLC integration A man always has two reasons for b
35. arter igniter i 78 Shut off torch fuel 96 Run State Run 96 speed Engine Starting Administrator Screen to Change Fault Settings Ignition tempcraturc Hung start times lempcrature exceedences starting and running Speed exceedences Monitor Start State Verily that have ignition Verify vil pressure Verily temperature profile in range Verify start timing Verify speed range Monitor Run State Verily oil pressure Verily temperature profile in run range Verily speed range 95 105 Run is ended for 1 User commanded shut down 2 Engine faults with an appropriate display Figure 4 Solar Flowchart Faults By automating the sequence with the PLC not only can it be started more smoothly reliably but it is also safer and easier to troubleshoot engine when the engine doe not perform as desired Some of the faults detected with the program include 1 Failure to light ensures fuel ignition occurs by checking if a set temperature is reached within a prescribed time from the starting 2 Temperature limits The engine has to stay within pre defined temperature ranges for both starting and steady state running 3 Hung start The engine has to reach 100 and intermediate speeds within a desired time and is not allowed to slow down or reverse speed during starting 4 Loss of oil pressure Oil pressure has to be maintained at a given pressure to continue operation
36. dition al DLOG PLC The tasks performed by each of the four DL06s include keeping track of the number of completed cycles for each dishwasher monitoring the test rack drain pump safety circuit staggering dishwasher start delays when lost utili ty facility power is restored and energiz ing soap injection pumps at the start of each main wash cycle The PLC for each rack receives a signal from each dishwasher at the beginning of the main wash cycle The www automationnotebook com PLC subsequently energizes a small pump which injects the appropriate amount of soap into the dishwasher There are 16 DC pumps for each rack one for each dishwasher These pumps are external to the dishwashers as they are components of the test racks The two additional DLOG PLCs control the two test racks that belong to reliability engineering and control air cylinders that push dishwasher cycle and start buttons The relay outputs of the PLCs operate air control valves which in turn operate the air cylinders To operate a Viking Range dishwasher users must push control panel buttons while the door is open We designed the dishwasher test stands with relays that simulate opening the door We use small 4 inch air cylinders that physically push the wash cycle and start buttons The air cylinders are posi tioned at the top of the dishwashers at each test position Tests start every 2 5 hours and continue to loop 24 7 Dishwasher current dra
37. e one move CTAXDYNP Axis Mode Dynamic Position puts the axis in a mode in which it accepts new position commands as quickly as you can generate them The output will follow the Axis Configuration parameters and immediately head toward a new target CTAXDYNV Axis Mode Dynamic Velocity puts the axis in a mode to accept new velocity commands as quickly as you can generate them When a servo is too much and a stepper isn t quite enough simple closed loop control might do the trick To bridge the gap between stepper control and a servo Do more and the H2 CTRIO2 offer integrated Encoder Feedback It s part of the CTAXCFG Axis Mode Configuration ladder instruction Specify an encoder to use for feedback and Deadband and your stepper encoder just became a closed loop system Scaling choose However a servo can detect a stalled and be needed if your system requires this notification motor additional code would Once configured for Encoder Feedback the other Axis Mode instruc tions are used to command moves using units of the encoder More on that follows Easier programming commissioning maintenance To ease programming and maintenance the H2 CTRIO2 configuration is part of the CPU s project The Do more CPU configures the module for you which is handy during commissioning This greatly simplifies the task of replacing a module just set the jumpers to match the original and swap the units
38. e sensitive labels After expanding into the tag market in 1997 the company moved into its current custom built facility in Canton Mich Today American Label amp Tag services the digital print on demand market using its capabilities to produce all required artwork graphics design and plate making In addition the company is a national distributor of printers software bar coding systems and The sells tags accessories labels and and internationally American Label amp Tag prides itself on having team members who are company nationally problem solvers not just order takers The company is a great representation of American manufacturing and its maintenance supervisor Bill Dobiesz is an equally great example of American ingenuity When Dobiesz started working at the company s Canton plant in October 2003 there were four Markem LP 195 hot stamp presses at the facility but only one was operational The machines were no longer being supported by the manufacturer so over the years three of the machines had been cannibalized for parts Many readers will recognize aspects of Dobiesz personality in themselves he 18 was the kid who would take apart the vacuum cleaner and the telephone to figure out how they worked His mechanical inclination led him to the career he has today in which his spirit of learning how things work has made him a valuable asset to the company Not content to see the machines
39. eace and at ease must not speak all he knows or all he sees Benjamin Franklin www automationnotebook com 2 7 Student Spotlight JEP Engine yp WAUTOMATIONDIRECT Gas Turbine repurposed with PLCs By William Rossey Midwest Propulsion Group he Midwest Propulsion Group is a jet engine club dedicated to increasing the engineering knowledge and experience base of students by providing engineering tasks related to gas turbine real world restoration and performance analysis as well as finding vehicular applications for such engines and the Cincinnati Dayton area and engineer students from Comprised of professional engineers ing co ops from varying universities the group meets weekly to increase hands on knowledge of younger engineers while having fun and also promoting engineering at local high schools and aerospace venues The team is currently using DirectLOGIC programmable logic controllers PLCs to automate the starting sequence of gas turbine engines as well as monitor performance to ensure the engines are operating within established parameters If the engines operate outside the desired envelope the PLCs terminate the operation and display the appropriate programmed fault Part I The Solar T62T 32A Hydro mechanical Engine The Solar T62T 32A gas turbine engine was originally installed in a automatically military generator set which included appropriate cont
40. ect is different Each industry has its own challenges Each task of the system requires unique skills From designing to programming to assembly to commissioning the variety keeps each day exciting What was the most difficult programming or engineering project you ever tackled using PLCs from AutomationDirect ya ane SAIN AARS mi j i ei V it Maples Rugs DirectLOGIC DL 205 control system for high speed dye application For Maples Rugs I developed a DirectLOGIC DL 205 controlled high speed dye application process that sprayed six different colors of dye into yarn as it sped through the machine at 1200 feet per minute The dye had to be sprayed in 0 0125 tolerances to apply the pattern desired The spray controls continually monitor the yarn tension and speed and adjust to fluctuations in real time Maples Rugs high speed dye application In addition to the dye application control system I developed a desktop pattern design application allowing the client s design department to create the tf i i pi FRRRKKKRARRKRTF Automaton vote hook WINTEr zZoiz Tssye Twenty four rug designs An interpretation of this To learn more about what KCC pattern was then converted and Software has to offer visit downloaded into the control system to www kccsoftware com apply the design exactly as desired The obstacles included getting the pattern KCC Softw
41. embedded communication port e Supports up to 256 I O locally and thousands more with optional Ethernet remote I O e Supports inexpensive serial port expansion for connection to bar code readers printers etc And each Do more CPU comes with a coupon for a 30 day free trial of online video training See guar Web ate for details and resinctions Copyright 2012 Automationtivect Cumming GA UAL All rights resemved ar s ci as Hi pies Hi SERIO d HF pei iim MEAL ATS CE T a TEA E E SEeUwee aye Built in simulator Program Do more with the completely new and FREE Do more Designer software DirectSOFT and ladder programs developed with DirectSOFT are not compatible with these CPUs Download the FREE software my Choose a Do more starter kit to get going fast You get e Prewired 3 slot base with your choice of Do more CPU e 8 point input simulator module e 8 point relay output module e Do more Designer software CD ROM ae USB programming cable e User manual BA J i Coupon for 30 days FREE u Git O online video training os i AutomationDirect reserves the right to s F gt xKx lt lt substitute a larger base at its discretion z Starter Kit H2 DM1E START H2 DM1 START with H2 DM1E CPU with H2 DM1 CPU So visit for the details watch overview videos and download the free software to take it for a spin Or go straight to to buy YAUTOMATIONDIRE
42. emental encoder signal and a PLC servo drive or other input devices Ideal for use with single ended or differential line driver encoder signals the modules feature three complementary inputs rated for 4 5 7 5 and 12 26 VDC and frequency response up to 1 MHz The FC ISO C high speed optical isolator module is designed with three complementary open collector outputs rated for 5 36 VDC that can be used in single ended configurations Optical isolation rated at 1800V separates the input signals from the outputs This module can convert a differential line driver encoder signal to an open collector single ended signal or change voltage to match encoder signal receiving electronics input The FC ISO D high speed optical isolator module is ideal for use with encoders and servo drive encoder signal inputs and outputs The module features three differential line driver outputs rated for 5VDC with 1800V optical The FC ISO D module converts single ended encoder isolation signals to differential line driver signals or differential line driver encoder signals to single ended signals The module can also change encoder signal voltage to match receiving electronics input Both modules are designed with a slim line plastic housing which includes an integral 35mm DIN rail mounting adapter LED indication and removable screw terminal blocks for easy installa tion and wiring The modules priced at 89 are UL508 listed and CE
43. er 49 Free award winning Tech Support 30 day money back guarantee e Incremental encoders with resolutions from 30 pulses revolution up to 5 000 ppr Hollow or standard shaft versions e Open collector line driver or totem pole outputs e Absolute encoders with gray code output in 32 to 1 024 pulses revolution ecx our our prices C GTD TITE Proximity 18mm round metal 3 wire NPN DC 14 00 82 26 Photoelectric shielded 5mm range with Q D PBK AN 1H 872C D5NN18 D4 5 to 18mm threaded round style or rectangular eraik A EE 39 00 109 08 Diffuse retroreflective through beam and background shielded ae BRNO gaa R suppression sensing models Proximity e Straight or right angle optics 18mm round 2 wire AC shielded 31 00 103 02 gt IP69K models 5mm range with 2 meter cable aS Fiber optic e Supreme noise protection and small sizes for tough applications e 18mm round and DIN rail amplifiers 4 6 and 7 mm fiber heads available 2 2 mm diameter cuttable plastic fibers a Inductive capacitive and ultrasonic technologies 3 mm to 30 mm round with standard sensing distance 8 mm to 30 mm round with double triple sensing distance Rectangular formats Stainless steel and IP69K round models Analog output models Embedded cables or quick disconnects in M8 and M12 aia oF ae i i oT t es Tgl i ee a n i p ga g T a oe n i pay if F p YAUTOMATIONDIRECT the 1 value in automati
44. ernation in New Ways Including a hibernation state is a valuable approach to improving TCO by reducing operating hours and energy Figure 1 This Propack dual infeed packaging machine accepts 350 granola bars per each of two sides The bars are loaded into a single stream of top load cartons in different counts depending on retail requirements and into bulk article January 2012 format cartons Courtesy of Control Designs Design for TCO Continued p 12 gt gt FRKKKRRKKKKAKARF i TELLE 6b bbbk a SX IRONHORSE e Cast iron Premium Efficiency motors up to 200 hp starting at 155 Single phase and three phase rolled steel general purpose motors up to 2 hp starting at 79 Marathon Inverter duty AC motors up to 100 hp starting at 143 DC motors up to 2 hp starting at 133 c n ee ah pi aTa ELN T Faris ce ve Br r g gr J E D S h ai e F F LFis e E D a See car Web site for detali and restrictions 2 Copyright 2017 AutomationDirect Cumming GA USA All rights reserved Ready for washdown and harsh environments lronHorse Stainless Steel AC motors are designed for use in applications where motors are frequently exposed to moisture humidity certain chemicals or other washdown environments NOT rated for direct contact with food All our lronhorse motors are in stock and ready for same day shipment if your order is
45. g While the large automation control suppliers thought it was a bad idea one company liked the concept That s when Koyo Electronics designers and manufacturers of PLCs for some of the world s largest automation companies turned small town of Cumming Georgia and made PLCDirect the first to sell micro PLCs promoting the Koyo brand to an their attention toward the through mass marketing already large installed base of its private branded products Since that time that small PLC company grew and became AutomationDirect But PLCs such as the well known DirectLOGIC series and newer entries such as CLICK are still the heart and core of the business For that we say Thank you Koyo Electronics This issue of NOTEBOOK is chock full of informative technical articles new product announcements and more Youll learn in our User Solution story how Viking Range uses products from AutomationDirect to turn out reliable cooking equipment You ll also see in our Student Spotlight how a group of students in Ohio are restoring gas turbines for alternative uses Plus our feature story details how a Michigan company breathed new life into old equipment Don t visit the ever popular Breakroom Test your wits forget to to see if you can solve the mind teasers But most of all sit back relax and turn the page D TJ Johns Coordinating Editor editor automationnotebook com www automationnotebook com Table of Co
46. gramming using the product manuals and the AutomationDirect Web site We found both the manuals and the Web site content to be very well written and easy to follow The optional analog input cards and the OPC communications to our PCs running Excel allow us to measure temperature and current without having to buy separate and expensive data loggers The availability of both serial and Ethernet communication ports on the PLCs facilitated the required PLC to PC connectivity The PLCs have enabled us to set up continuous component and product testing We ve been running these types of tests for more than seven years without any problems from AutomationDirect products Due to our success with products Viking Range now uses DL05 and DLOG PLCs in two other manufacturing plants for monitoring and testing products od AutomationDirect Faith is taking the first step even when you don t see the whole staircase Martin Luther King Jr I don t paint things I only paint the difference between things Henri Matisse FRERKKKRRKRKRRFRS NEW DC or Analog output High resolution k j 15 to 30 VDC operating voltage Along with our great prices you get Adjustable sensitivity CE cULus file E187310 IP67 rated Lifetime warranty Same day shipping when ordered by 6 pm EST with approved credit or credit card see Web site for details FREE 2 day or better delivery on most orders ov
47. h a 15 to 30VDC operating range and are fitted with an M12 quick disconnect The UK1 series offers six different output types single PNP dual PNP 4 20 mA only 0 10V only PNP and 0 10V and PNP and 4 20 mA Models are available in four different sensing ranges 50 400mm 100 900mm 150 1 600mm and 200 2 200mm The sensors are equipped with LED status indicators and a pushbutton teach feature for configuration of normally open and normally closed states for DC output models and for adjustable sensitivity on analog output models Backed with a lifetime warranty the UKI series is cULus CE and RoHS approved and prices start at 99 Learn more about ultrasonic sensors at www automationdirect com ultrasonic sensors Safety speed monitor relays AutomationDirect has added Dold safety speed relay modules to its line of safety products The BH5932 speed monitor relay module is designed to monitor two sensor inputs that are detecting rotating targets on a motor shaft This monitor relay features two channel operation and can be used for standstill and over speed monitoring of three phase motors When used as a standstill monitor a switch point is set just above the safe or normal operating speed When motor speed rises above this setting the relay opens to protect against motor damage The BH5932 relay module has an adjustable impulse per minute IPM range of 10 to 20 000
48. h diameter and have a temperature sensing range of 32 to 2100 degrees F Prices start at 33 25 View the full thermocouple sensors at line of www automationdirect com thermocouple sensors RTD adjustable immersion sensors have also been added With a tempera ture sensing range of 58 to 572 degrees F the RTD features a 100 ohm plat inum three wire element and is spring adjustable allowing for variable immer sion depths The integral bayonet cap makes installation quick and easy when used with a bayonet adapter or pipe clamp adapter RTD adjustable immer sion sensors are priced at 43 50 Learn more about RTD sensors at www automationdirect com RTD sensors Additional ProSense accessories include ceramic terminal blocks screw cover connection heads thermowells adjustable pipe clamp adapters and ther mocouple connectors For more information on ProSense temperature sensors visit www automationdirect com tem per ature sensors Industrial use data cables now available offers high quality data cables designed with impedances specific for RS 232 422 and RS 485 applications in AutomationDirect now low capacitance communication industrial environments The 24 AWG tinned copper conductors are constructed as twisted pairs to reduce electrical noise sensitivity and are available in one two or three pair color coded constructions Polyethylene conductor insulation provides very high insulation
49. he program load it and I m running says Dobiesz He has set up the ability to change the screen color when the predeter mined count is reached when any of the bypass functions are enabled or if guards are opened In addition the touchscreen beeps if a guard is opened an emergency stop is pushed or if the preset is reached By operating the other machines Dobiesz learned the best way to reset the counter was by having it appear on another screen Using this method the counter is easy to reset but requires a deliberate action to avoid mistakenly resetting it in the middle of a job He was also able to use the touch screen to add a shift counter that an Operator can reset to show how many jobs have been done in a shift a week a month or any other time period In addition Dobiesz also created a single cycle function similar to jog that allows the machine to execute one cycle then stop which is used to save materials during setup One feature of which he is particu larly proud is the mini batch counter An operator can set this counter so that the machine executes a certain number of cycles then stops This gives the operator time to clear the machine and stack parts before pressing the start but ton for the next mini batch The mini batch counter functions within the main counter so the machine is still keeping track of the total batch count Using Dobiesz solution i s possible to retrofit the entire a
50. hields with tinned copper drain wire enclosures across NEMA 1 e Polyethylene conductor insulation PVC jacket 35 3R 4 4X 6P 12 4 12 e 1 2 and 3 twisted pair cable styles and 13 ratings e 100 500 1000 foot lengths coil reels Signal and sensor terminal blocks and power distribution blocks VAUTOMATIONDIRECT the 1 value in automation See our Web sibe for details and resiictions o Copright 2002 AutomationDiect Cumming GA USA All rights reserved Student Spotlight Cont JEP Engine yp WAUTOMATIONDIRECT Continued from p 28 Figure 3 C more Touch Screen A view of the engine start up screen showing the temperature speed and inputs outputs from the PLC is shown in Figure 3 Once the engine start button is selected two major states run in parallel in the ladder logic the starting running state and the monitoring state which make sure the parameters of interest are within the appropriate limits The program switches from starting mode to running mode when the engine reaches 96 speed at which point the torch nozzle is also disengaged A simplified programming flowchart is shown in Figure 4 30 Test Screen Manually actuate Transfer pump Starter Tyniter Torch fuel solenoid Main luel Solenoid Initializing Stage Start State Automated Transfer pump Starter lgniter Torch fuel solenoid 4 Main fucl Solenoid 10 Shut off st
51. ing to start test runs of the gas turbine itself Once the engine runs reli ably the focus will shift to varying the generator output based on user demand Also the team now plans to use the Solar T621 32A gas turbine engine to power a hovercraft instead of in the original automotive application To learn more about the various club projects feel free to contact William Rossey at therosseys cinci rr com A good film is when the price of the dinner the theatre admission and the babysitter were worth it Alfred Hitchcock 33 The Break Room Brainteasers amp Humor WAUTOMATIONDIRECT Punny stuff from the Internet King Ozymandias of Assyria was running low on cash after years of war with the Hittites His last great possession was the Star of the Euphrates the most valuable diamond in the ancient world Desperate he went to Croesus the pawnbroker to ask for a loan Croesus said I ll give you 100 000 dinars for it But I paid a million dinars for it the King protested Don t you know who I am I am the king Croesus replied When you wish to pawn a star makes no difference who you are A famous Viking explorer returned home from a voyage and found his name missing from the town register His wife insisted on complaining to the local civic official who apologized profusely saying I must have taken Leif off my census An Indian chief was feeling very sic
52. initial price expenses that may or may not occur during its service life need to be calculated to determine how much the machine will cost over its lifespan This is called the total cost of ownership TCO and is a critical factor in the purchasing process of a machine but one that is often overlooked In addition to the initial costs such as the purchase price and the cost of integrating the machine or equipment into the overall control system buyers need to the operating before purchase A bargain isn t a bargain if it consider long term costs making a will require unusually high amounts of energy and maintenance Buyers must also consider additional factors in the TCO and changeover expenses off spec product equation downtime floor space requirements insurance financing costs training security and safety among other expenses 10 Unfortunately these considerations arent as easy to make as they are for a consumer product such as a laptop or a smartphone Machine builder OEMs need to realize the features that reduce customers TCO may increase the cost of their Corresponding higher prices may scare off customers so OEMs need to decide how to best their long term savings in order to justify the machines educate customers about higher purchase price Importance of Energy Efficiency As energy costs continue to rise most customers are looking for greater energy efficiency from their machines
53. k so he summoned the medicine man After a brief examination the medicine man took out a long thin strip of elk rawhide and gave it to the chief telling him to bite off chew and swallow one inch of the leather every day After a month the medicine man returned to see how the chief was feeling The chief shrugged and said The thong is ended but the malady lingers on Evidence has been found that William Tell and his family were avid bowlers Unfortunately all the Swiss League records were destroyed in a fire So we ll never know for whom the Tells bowled 34 Brainteasers 1 Widget Not The WidgetMaker2000 had only been making widgets for an hour before something in the drive train malfunctioned The machine had to finish the production run at 3 5ths of its normal speed This caused a two hour delay for the completion of the production run The operator explained that if the machine could have finished just 50 more widgets before experiencing trouble the delay would have been forty minutes shorter Can you determine how many widgets were produced in this production run 2 Hardheaded Flooring A hardwood floor manufacturer produces boxes of floor ing with exactly 297 linear feet of flooring They require that each box contain 16 pieces with each piece being an even number of feet in length They also promise that eight of those pieces will be of the longest length with the remaining pieces made up of some combination
54. lest Standard Type B USB programming port control system e 15 pin serial communications port Enhanced objects and graphics 320 x 240 resolution 3 2 MB memory e Mounting variations for key orientation The programming software is free when downloaded from the AutomationDirect ee Web site or the CD ROM package can be purchased for 25 part EA MG PGMSW Up to 999 screens dependent on complexity e Recipes Built in project simulator at Popular protocols devices supported UL cUL CE NEMA4 and 4X indoor ratings All AutomationDirect programmable controllers Modbus RTU Allen Bradley DF1 half full duplex PLC 5 DF1 and DH485 Siemens PPI GE SNPX Omron Host Link and FINS serial Mitsubishi MELSEC Go online for complete list HOW Ue VIDEOS ie e 6 inch STN and TFT touch panels 3 inch touch and Optional plug and play non touch panels keypad bezels for 3 and 6 inch models ji FRARRKRIR Check out over 80 C More Micro tutorials online AUTOMATIONDIRECT the 1 value in automation See oi Web ate for details ard resinchont Copyright 2012 Automationdirect Cumming GA USA AN rights menard Automaton wore book WINTEr zoz Tssy Twenty four NOTEBOOK Your guarde TO PY ACACAl PIOAYCTS 7ECANOIO9IES and applicatons TERETE Contributors Publisher Tina Gable Managing Editor Joan Welty Coordinating Editor TJ Johns Desig
55. lows a computer program to run a high pressure fuel pump to achieve the desired speeds The FADEC sends 24V pulses to the pump of varying duration pulse width modulation PWM to accelerate or decelerate the engine There are no mechanical inputs to the controller The only inputs are engine speed variable engine temperature variable and oil pressure discrete From data logging the engine supplies limited documentation it was found that the and from the start up with a pre defined fixed out put Once the engine reaches 50 speed the PLC switches control to a commercial digital engine governor to vary the output to the high pressure pump and keep it at desired speed The PLC accessories in actuates all the sequence and switches from the starting PWM circuit also to governor control In addition the larger DOG PLC with more relays and card slots was selected to allow for future automation For example the intended application requires use of the gas turbine electrical generator to make a turbine electric go kart To vary the throttle electrical output a control circuit will have to be made that will also be actuated automated by the PLC Status At press time the team was www automationnotebook com DAY ireny Bon Sey Figure 6 Data Logging parameters recorded in the process of finishing bench tests finalizing programming of the touch screen in the test stand and was prepar
56. marked and are backed with a one year warranty For more information visit www automationdirect com signal conditioners Industrial safety gloves AutomationDirects lineup of wearable safety gear now includes safety gloves and sleeves Styles available offer high levels of cut puncture and impact resistance and are available in sizes rang ing from extra small to extra extra large depending on glove type Among styles offered general purpose gloves feature nylon yarn construction with polyurethane coating for superb grip and excellent dexterity Anti static work gloves are ambidextrous and protect both your hands and product from electrostatic build up while providing maximum dexterity Additional glove types available include cut resistant styles made of steel core cut resistant knit certain styles feature reinforced thumb webbing stitching Drivers glove style electric arc resistant gloves feature full grain goatskin leather and steel core cut resistant lining www automationnotebook com Mechanic style work gloves are form fitting for excellent dexterity and are fitted with cow grain leather palms and woven nylon backs Excellent general purpose gloves they also feature adjustable Velcro wrist closure for proper fit Available puncture resistant styles feature full palm and inside finger protection as well as impact resistant knuckle padding More details regarding the full line of industrial gloves
57. n Manager Justin Stegall Contributing Writers Christine Lesher Sammy Natsui Barry Hupp Jason Horine Tim Roberts William Rossey CONTACTS Automationdirect com Inc 3505 Hutchinson Road Cumming GA 30040 Phone 1 800 633 0405 or 1 770 889 2858 Fax 1 770 889 7876 Monday Friday 9 a m to 6 00 p m EST www automationdirect com Copyright 2012 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 If you are a non subscriber and would like to be included in the next mailing of AutomationNotebook please visit http www automationnotebook com freestuff html on the Notebook 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 Automation 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 us in person please call 1 800 633 0405 x1845 Thanks for your interest and we look forward to hearing from you Editors Note Back in 1994 a tiny company known as PLCDirect was formed on the idea of making PLC products available through a direct sales catalo
58. ng to improve data management and data structures to simplify initial programming and long term software maintenance The PLC Do more enables developers to write program code before selecting the specific target hardware Nicknames can be assigned to inputs and outputs then later tied to the physical configuration Within data memory the developer can allocate partition size by variable types for maximum flexibility Natsu further advantages of the new software saying With a wide array of high level program blocks in Do more developers points out can use two or three instructions to program functionality that used to require of hard to understand ladder logic This simplifies many lines and speeds development and also promotes standardization For example the Spreadsheet style MATH instruc tion allows mixing of data types and accepts formulas and variables The MATH instruction also allows nesting with parentheses to 8 levels and supports Trig and Statistical functions built in simulator creates a virtual PLC so logic can be tested without a PLC present Do more Designer s The tool simulates discrete and analog I O with access to timers counters and control bits as well as the PID function The generation high speed counter module H2 CTRIO2 priced at 299 has four independently counter channels up to 250 kHz and accompanying next configurable timer two pulse output generators
59. ntents New Product Focus 4 AutomationDirect launches new Do more PLC and Counter Module Product Snapshots 6 IronHorse stainless steel general purpose AC motors More ultrasonic sensor choices Safety speed monitor relays High speed optical isolators Industrial safety gloves Dual rod guided pneumatic air cylinders ProSense room temperature sensors and Type T ther mocouples Industrial use data cables Cover Story 10 Reducing Total Cost of Ownership Product Management Corner 16 Do more PLC Feature Story 18 Bringing Life to an Old Machine User Solutions 20 PLCs Automate Reliability Testing System Integrator Corner 24 KCC Software Tech Brief 26 Motion with Do more PLCs Student Spotlight 28 Jet Engine Club Break Room 34 BrainTeasers amp Humor New Product Focus WAAS Mu VAUTOMATIONDIRECT AutomationDirect launches new Do more PLC and Counter Module DL205 CPUs Higher processor speeds not only decrease program execution time but also allow the CPUs to support Ethernet connectivity and custom communication protocols as built in functions says Sammy Natsul PLC product manager A Do more CPU installed in a DL205 9 slot base supports up to 256 I O points The I O Configuration window performs full auto discovery of all I O modules in the local base simplifying system configuration AutomationDirect s For larger applica tions one or more Remote I O
60. ntrol panel with the DLO5 PLC signal conditioning modules and fuel governor can be seen in Figure 2 Programming flowchart Using a C more touchscreen the Operator enters a menu screen and then chooses one of the following options 1 Run the engine 2 Test the outputs actuate each output independently to verify functionality 3 Administrator screen adjusts fault setting for both start up and steady state running Continued p 30 gt gt L PARN FRFRFRRKRAKFR PEPE P PPL e From cable to enclosures AutomationDirect has some of the best prices available for cables wire duct and wire terminal blocks and even the enclosures to put it all in Our latest addition of communication data cables are a direct equivalent of popular brands So check out our prices to see RAY how we can help you stretch your controls budget Pa 500 reels starting at 279 00 Cat5e STP L19772 500 Twisted Pairs with overall Shield Ethernet ri ds Patch Cabl 100 coil Pru Wal starting at 66 00 L19772 100 Wire duct and flexible tubing 1000 reels starting at 455 00 19772 1000 High quality low capacitance data cables are designed with impedances specific for RS 232 RS 422 and RS 485 communication applications in industrial environments Choose from over 1 600 e 24 AWG tinned copper twisted pair conductors Hubbell Wiegmann e Foil and braided s
61. o learn how the machine worked on his own because the operational sister machine was at the companys other plant in Daytona Beach Fla Moreover two of the items that had been stripped for use in the other the switchboard and the electromechanical the system machine were control machine s The was still counter basically entire automation electromechanical counter available but it was expensive and limited in functionality Searching for a better solution Dobiesz saw a magazine ad for the CLICK PLC from AutomationDirect Confident in his abilities he used his own money to buy the PLC and a power supply He was able to do this because the CLICK PLC was very economically priced and because the downloadable programming software was free Small Size Big Performance In addition to its low price and long list of capabilities the CLICK PLC was very small Unlike any of other printing machines at the company this one had all the controls in a removable the new PLC drawer Installing anywhere but in this drawer would have presented problems and the CLICK PLC s small size made this option a reality The CLICK PLC fits easily into the removable drawer where it had to be installed After purchasing the CLICK PLC Dobiesz realized hed also need to provide an operator interface for the machine so he naturally turned to ox on e e ot e e e e e F TITIES
62. o use configuration software by downloading a demo version at http support automationdirect com demos html e Analog resistive touch screen with unlimited touch areas e One USB A type and one USB B type port e Serial communications interface e 10 100Base T Ethernet communications e CompactFlash slot for data logging No Additional Hardware required The C more Remote Access feature resides in all panels with Ethernet support and requires no option modules Access real time data or initiate an action on a control system from anywhere any time Requires software and firmware version 2 4 or later and an Ethernet C more panel C more touch panel line up 6 inch STN 6 inch TFT grayscale 65 538 colors Free standard shipping is available for orders totaling over 49 U S except for orders which require LTL shipping see Web site for details Also save on brokerage fees when shipping standard ground to Canada you can choose to allow AutomationDirect to nominate a Starting at broker for your shipment for parts shipping via standard ground 432 This can save you big on brokerage fees See Web site for details and restrictions a p p P a al xy ws O i ey f T aa Va hine Tadaut AMPS roday See Or Web yie tor detai and Peston Copyright 2012 AutomatonDirect Cumming GA USA AS fights reserved more Starting at C more operator touch panels offer e Clear TFT 65K color displays 6
63. on ay ME F ns i Fala Fl wr f i Lace y ric See mur Web ste for daai and restrictions Copyright 2012 AutomatonD rect Cumming GA USA AN rights reserved TITI System Integrator Corner WAUTOMATIONDIRECT SOFTWARE lt Sipirecr AUTOMATION ODIRECT utomationDirect is proud to have a network of system integrators covering a wide variety of industrial control processes across the country KCC Software Alabama provides services in all areas of the United States and in several countries around the world Tim Roberts Coordinator for AutomationDirect recently talked with KCC Software owner and founder Scott Martin to in Huntsville Integrator learn more of what he and his company have to offer How did you get started in your Controls Engineering career I moved from programming Space Station automation to a mechanical systems department of my employer This introduced me to the world of control systems in the semiconductor industry I entered as a programmer and quickly fell in love with the bigger picture of systems integration with programming being my specialty How long have you been doing Systems Integration work I started this work in 1986 and have been fully immersed ever since 26 years now Now at least 25 of sys tems I develop and deliver involve replacing 1980s and 1990s micro processor systems with PLCs What was the most interesting applica ti
64. on in which you have used PLCs from AutomationDirect For IBM s Watson Research Center I developed the Silane distribution system Silane is a volatile gas that ignites when exposed to atmosphere Storing it under significant pressure and distributing it through the center 24 Silane distribution system for IBM s Watson Research Center comprises a true challenge Everything has to be controlled and monitored continuously throughout the facility in order to avoid catastrophic possibilities The solution included a series of DirectLOGIC DL 205 PLCs networked and in constant communication to share the task of safe gas containment and delivery In addition to networked PLCs the project also used C more HMI panels throughout the facility and in research labs as well as a PC based Think amp Do system for site wide status monitoring and alarm and event historical logging What made that project unique challenging The gas delivery covers hundreds of feet of monitored tubing with potential ly fast acting pressure and temperature changes that have to be controlled for the safety of all concerned Due to the high pressures and flammable nature of the gas involved the constant commu nication between PLCs for shared con trol was challenging not only for what had to happen normally but also for what had to happen when anything unexpected occurred What is a favorite aspect of integration to you Variety every proj
65. or current measurements were required we simply added an analog input module Over the years weve changed the test fixtures and PLC configurations to accommodate our reliability testing requirements Today we still use part of the original dishwasher test lab but instead of the DLOG PLCs we started with we use three DLO5 PLCs These PLCs are mounted on custom stands that test individual dishwasher parts such as soap dispensers and pump and drain motors Other dishwasher life testing tasks we ve added include a door cycle fixture for opening and closing a dishwasher door from 30 000 to 50 000 times Figure 2 This custom door cycle fixture performs life testing by opening and closing a wall oven door up to 50 000 times depending on test requirements Figure 2 an upper slide rack fixture that tests a dishwashers upper rack by sliding it in and out and a fixture that tests dishwasher water valves by cycling them on and off repeatedly The primary dishwasher test lab has four dishwasher life test racks with 16 test stations for each rack A test station is where testing of an individual product such as a dishwasher takes place where as a rack consists of multiple test stations grouped together Dishwasher design engineering uses two of the four racks in the dishwasher test lab and reliability engineering uses the other two Each of the four racks has a DLO6 PLC and the two reliability engineering racks each have an ad
66. otors LH5946 series motor standstill safety relays monitor voltage to provide safe standstill detection on 3 phase and single phase motors The LH5946 series offers adjustable response ranges and adjustable time delay Both series are available in 24VDC 120VAC and 230VAC supply voltage versions k or MISU if Safety Switches Safety Light Curtains vorEp Order Today 3 Sh ip s Today 14 VEARS i i al d a Ei eat Gee our Web site for detalls and restrictions Copyright 2012 Agtemationfirect Cumming GA USA All nights reserved JUST A FEW PRICES ON SAFETY DEVICES AutomationDirect Price Part Number Safety light curtain with 30mm resolution 277 00 24VDC sender and receiver pair YBB 3054 0250 G012 sender sold separately 0 25 to 12 meter operating 305 00 distance 279mm protective height safety category 4 YBB 30R4 0250 G012 receiver Safety limit switch pull reset action plunger S 13 00 actuator 30mm plastic body 1 2 NPT PRAKTI Safety relay module single channel for 88 00 E stop circuits 24 VDC 2 N O contacts LG5924 02 61 24 AutomationDirect prices are U S published prices from April 2012 Price List Prices subject to change without notice VAUTOMATIONDIRECT the 1 value in automation co 020D1 D qua Thirteen stackable discrete O option modules 8 max per CPU Add an HMI for as little as tom 161 table cate You can t get started in PL
67. over 49 you get free shipping too e 0 33 to 2 hp three phase e 1800 and 3600 RPM e Standard NEMA 56C frame e Available with or without mounting feet e Totally enclosed fan cooled e 304stainless frame and base 303 stainless motor shaft e No restriction on mounting orientation e IP66 cord grip included YAUTOMATIONDIRECT a ri the 1 value in automation Cover Story cont WAUTOMATIONDIRECT RELE Or Aing losts Continued from p 10 use In the Control Design January 2012 story Design for TCO Derek Jones marketing manager at Lantech www lantech com comments Our machines only run when product is fed to the machine During downtime the machine is not using much power at all The Control Design article also looks at how the Canadian company Propack Processing amp Packaging Systems www propack on ca which builds robotic collators to feed topload endload and multipack packaging machines uses hibernation to improve TCO Figure 1 Propack s machines typically run three shifts per day Chris Follows president says If no product is available we turn off all the conveyors that feed the machine This also ensures cartons are not damaged due to conveyor friction A hibernation cycle can go beyond reducing energy costs for operating the machine By reducing the time a machine is running at full load users also reduce the amount of heat generat ed throughout the o
68. perations shift thus lowering cooling costs Many customers may not be aware of the machines features that can help them save energy such as automatic sleep mode According to the Control Design story a recent study in the automotive industry quantified the potential savings of putting systems into a sleep hibernate or standby mode when not actively producing value The analysis concluded potential savings of up to 30 percent could be achieved Hibernation can be a good way to reduce energy costs but it can t be sim ply added without carefully reviewing how it may affect other systems within the plant Determining how to design and implement hibernation states require careful study such as determin ing when to save energy by shutting the systems down or when it s better to leave them on Machine builders also need to examine the effects from the plant floor 12 to an ERP system One way to ensure a hibernation scheme is compatible with workflow and other production realities is to transfer I O data to an ERP or MES Automation Keeps Costs Down The customers calculation of reducing TCO but competitive machine pricing is a careful balancing act for industrial OEMs The latest automation technology can help these OEMs requirements without having to sacrifice maintaining meet customer their profit margins In the Control Design story Howard Dittmer vice president of engineering and technology
69. resistance The rugged gray PVC jacket is durable enough for use in demanding industrial applications Protection radiated or conducted electromagnetic interference is provided by combination shields consisting of an overall foil shield layer from with drain wire and a woven braid shield layer This shield combination offers maximum effectiveness across the frequency spectrum compared to other single layer shielded cables Data cables are backed with a one year warranty and are available in 100 foot coils and 500 or 1 000 foot rolls with prices starting at 69 for a 100 foot coil For more information visit www automationdirect com data cables EE FRR RKKKRKKKKRRFI TITTI Arc Flash amp Cut Resistant Gloves oe Industrial Work Gloves for Hand Protection AutomationDirect now offers a variety of protective gloves for industrial or other hazardous environments From light weight nylon to leather or steel core yarn you ll find what you need for specific working tasks Cut resistant gloves and sleeves meet the ANSI standard up to cut level 5 Most gloves are available in sizes from extra small to 2XL Prices start at just 7 00 for a six pair package of general purpose polyurethane coated nylon gloves General Purpose Working Gloves Anti Static Gloves Arc Flash Cut Resistant Gloves Cut and Puncture Resistant Gloves Mechanics Style Gloves Impact Puncture Cut Resistant Gloves
70. rol system Brian Engle design engineer at Industrial Technology Solutions ITS gives a good example of this when discussing a horizontal bender at a conduit manufacturer customer The horizontal bender required seemingly endless adjustments that dragged down productivity It was controlled with manually operated that had to be manipulated by two operators to achieve the necessary bend angle A hard limit hydraulic valves switch was used to control the travel of the bending die Travel had to be adjusted constantly for variations in the pipe and the material size inconsistencies in The process of segment bending needed very precise control to achieve a quality product Operators had to make several precise smaller bends while moving the pipe forward in the shoe In addition to a long setup time an amount of enormous scrap Was produced before good product could roll off If a job calls for say making 90 degree elbows with a 60 inch radius from 2 inch galvanized rigid conduit there is no standard shoe for that So this machine is used to make small quantities of non standard products explains Engle Instead of sticking with the old process the manufacturer asked ITS to modernize the control system with an HMI PLC and sensors from AutomationDirect Figure 3 The new system uses a magnetic cumbersome encoder on the bending die to track bend angle while analyzing the bending pipe inconsistency
71. rols to start up and run the engine to provide desired electrical power The gas turbine runs at approximately 60 000 RPM and was geared down through a planetary gearbox to 6 000 RPM which then drove a 3 phase 60kW AC generator The controls needed to be redesigned since the original controls were not available and the intended application changed A view of the gas 28 turbine removed from the generator is shown in Figure 1 Figure 1 Solar T62 The engine start up operational sequence follows 1 When the system is powered up the transfer pump is turned on 2 Once the start command is initiated the electric starter and igniter turn on simultaneously 3 At 4 engine speed a single fuel nozzle is opened torch nozzle and combustion begins 4 When the engine accelerates to 10 speed the fuel manifold is opened with six fuel nozzles main fuel 5 Once the engine reaches 78 speed the starter and igniter disengage the engine speed keeps accelerating on its own power 6 At 96 speed the torch nozzle is disengaged and the engine continues running at 100 which corresponds to a frequency of 2 000 Hz on the magnetic pick up The original generator configura tion monitored the oil pressure exhaust gas temperature EGT and speed If any of the parameters exceeded established limits such as a loss of oil pressure or the engine got too hot the engine would shut down The engine has hydro mechanical
72. sitting idle Dobiesz devoted extensive time and effort including making some parts on his own to get two of the forgotten machines operational It was a project he did largely on his own time and with his own money as he couldn t resist the challenge During the project he got to know the machines pretty well from the inside out He knew they were high quality hot stamp presses and he was determined that the problem of unavailable replacement parts wouldn t stop him Taking on New Challenges The economic downturn in 2008 affected many companies and American Label amp Tag was no exception Fortunately American Label amp Tag has a very hands on owner who is involved in the business at every level He knew he had many good employees who would be willing to learn other job duties to help the company through the recession Dobiesz thought that he could get the hot stamp presses running again so he volunteered to work on them At one point he told Tim Gleason president of American Label amp Tag he wished he hadn t taken the other Markem LP 195 machine to Florida because he thought he could get it running Gleason had faith in him because one phone call and two days later the machine arrived back in Michigan But Dobiesz thought he The Markem LP 195 hot stamp press when it arrived back in Michigan in dire need of attention might have made a big mistake when he saw the state of the machine Dobiesz had t
73. tion set The Do more instruction set was newly designed for the Do more PLC We understand it can often be time consuming and painful to learn a new instruction set We could have just added some new functions to the DirectLOGIC instruction set to extend its capability but that would ultimately have been limiting Do more has 172 instructions many of which can replace dozens of lines of DirectLOGIC code for a similar task I use the Instruction Palette to find what I need CPUs we could have positioned it as such price wise However the engineers at Host Engineering had low cost as a design goal and AutomationDirect as a result offer the modules at very attractive prices Future of Do more PLC The reason Host Engineering chose the DL205 hardware as the platform for the first Do more PLC is because it was faster to release by using readily available and time tested I O and base units However we know that using the existing DirectLOGIC hardware limits the performance of the can Do more PLC for the future we are developing ideas to create new hardware platforms that will performance that the Do more PLC maximize can provide Conclusion You dont need to replace your existing DL205 PLC system with this Do more PLC We will keep selling the DL205 PLC as long as we can after all we are still selling the DL305 PLC after almost 30 years on the market What we hope is that you will try the H4 lt FH er
74. tronic timer failed and the parts were no longer available Dobiesz was able to use the programming experience he gained from the hot stamp printing machines to fix his own washing machine and it ran several more years until it developed mechanical issues Dobiesz the C more touchscreen he had bought for reprogrammed the washing machine and he now uses it as a detachable testing device for his other projects at the plant He says that he s been able to successfully complete the economical prices AutomationDirect many projects because of offers and because of the Customer Forum where he knows he can always quickly get any assistance he needs 19 User Solutions VIKIMG RANGE WAUTOMATIONDIRECT PLCs Automate Reliability Testing AutomationDirect PLCs enable continuous life cycle testing provide data collection and shorten product design and verification cycles at Viking Range By Barry Hupp Reliability Manager Viking Range Greenwood Miss VIKING PROFESSIONAL hen Fred Carl Jr was designing his house in the early 1980s he wasn t satisfied with the quality of available ranges He came up with his own range design and soon thereafter launched Viking Range www vikingrange com Viking Range was established on Carl s requirements for high reliability and quality a mandate that has been carried forward ever since Although contract manufacturers in California
75. uality products with superior reliability to their demanding customer base FREARRKKKRKAKF Sees eeEEEES AuTomanon Mote hook Winter zoliz Tssye Twenty four The chief engineer on the dishwasher project wanted the major components tested to ensure a statistically high level of reliability We created designed and built six test stands to ensure dishwasher components exceeded Association of Home Appliance Manufacturers AHAM and Viking Range standards for long term reliability AHAM ANSl accredited standards development organization that develops is an and maintains technical standards for various appliances to provide uniform repeatable procedures for measuring specific product characteristics and performance features The components to be tested were dishwasher motors drain pumps water valves soap dispensers water heaters and heaters blowers for drying the dishes We built a separate test stand or fixture for each of these part component types and each of the six test fixtures had the capacity to test 22 components A DLO6 PLC controlled each test fixture except for the water valve test fix ture which used a DLO5 PLC We built the test fixtures to simulate how these components would be used in a dishwasher For example a water valve may come on for 70 seconds to put water into the dishwasher five times during a wash cycle We used a PLC to control the timing cycle When temperature
76. usiness has served my clients and my doing anything a good reason and the business very well Without real reason AutomationDirect this likely never J P Morgan would have happened www automationnotebook com 25 TIT Tech Brief bo more PLC amp W2z CTRIOz WAUTOMATIONDIRECT Ease of Motion with Do more PLC and the H2 CTRIO2 By Jason Horine art of the vision for the Do more PLC control engine was to make maximum use of Host Engineering s next generation High Speed Counter and Pulse Output module the H2 CTRIO2 Pairing this new module with a Do more CPU creates a solid motion control package that is easier to use than its predecessors while offering more flexible options and capabilities Background H2 CTRIO capable but limited by DirectLOGIC s architecture The previous H2 CTRIO module brought high speed counting and pulse output capabilities to the DirectLOGIC PLC line The H2 CTRIO took on the processing of these functions within the had its own configuration tool and files to save and load Since the CPU lacked the ability to assist with these tasks the package was module and as a result somewhat limited in scope but the combination satisfied many basic motion applications A better way While developing the Do more CPUs and the H2 CTRIO2 Host Engineering took ownership of develop ing a new solution Having designed the programming software CPUs and H2 CTRIO
77. utomation system of any existing Markem LP 195 or LP 385 machine with a low cost high and AutomationDirect control system consisting of a CLICK PLC and a C more Micro Graphic touch panel performing reliable The Markem LP 195 hot stamp press today after Dobiesz retrofitting of the automation system Great Help from Real Users As the CLICK PLC and the C more touchscreen were new to Dobiesz he needed assistance with many tasks from basic installation www automationnotebook com practices to programming He found AutomationDirect s Customer Forum to be a great help as he could discuss his situation with other users who would walk him through solutions in real time online The AutomationDirect Customer Forum is one of the biggest and best user groups in the automation world says Dobiesz There were helpful replies from the AutomationDirect tech people to be sure but the ground zero hold my hand and walk me through it advice I needed was from other forum members I m happy to share my infor mation with others I m known as Detroitsound Maybe I can help someone who is struggling as I was so that they too can get the personal triumph of solving a problem of their own offers Dobiesz As Dobiesz was now familiar with the CLICK PLC touchscreen he decided to use these and C more components on weekend project namely an older washing machine in his house that was no longer running The elec
78. w and power consumption are monitored using AC voltage and current transducers connected to an industrial PC Continued p 22 gt gt 21 User Solutions Cont VIKIMG RANGE WAUTOMATIONDIRECT Continued from p 21 Cooking and Refrigeration Test Runs Hot and Cold The main reliability lab also known as the cooking and refrigeration test lab is our largest testing facility Here we test ranges wall ovens cook tops and compactors Our cooking and refrigerators ice makers refrigeration test lab uses more PLCs than the other labs with most of them monitoring range temperatures The DL06 PLCs operate test stands and control cycle times For example cycle times for ranges can be 30 minutes on and 10 minutes off for 6 000 cycles Range and wall oven doors receive rigorous workouts as well In the cook ing and refrigeration test lab two test stands each with a DL05 and C more HMI operate and monitor the range and wall oven door open and close cycles The HMIs display the cycle counts while the touch screen keyboard allows test engineers to reset the count Some of the DLO6 PLCs are configured to measure current draw of electric ranges and cook tops AC current transducers measure the current usage monitored by the PLCs and collect data for graphing this current DL06 PLCs measure temperatures of ranges ovens and cook tops under test Thermocouples are attached to analog inputs cards The PLCs are
79. y ported five port four way spool valves 1 8 to 1 2 NPT port sizes Single or double pilot operation start at 14 00 Toggle hand lever and push pull styles with body ported five port spool valves in 1 8 and 1 4 NPT port sizes 4 port rotary valve stye in 1 4 and 1 2 NPT port sizes Foot pedal valves with guard are 5 port spool valves with 1 4 NPT ports momentary or latching models start at 4 75 8 10 and 18mm pin spacing DIN 43650 form cables 9 4 and 11mm DIN style cables 24 110 and 230 VAC DC models available PVC jacketed cables in 1 3 or 5 meter lengths start at 4 00 5 pack 10 different styles including Tee and elbow Male and female connectors in 1 8 to 1 2 NPT sizes Work with water oil air and other gases Maximum pressure 800 psi start at 5 00 Plugs and couplers for 1 4 and 3 8 inch hose sizes Male and female NPT threaded Compatible with three of the most popular connection styles VAUTOMATIONDIRECT the 1 value in automation Feature Story American Lapel 2 TAg WYAUTOMATIONDIRECT Bringing Life to an Old Machine An innovative employee at American Label amp Tag was an automation neophyte but AutomationDirect s customer support showed him the way By Christine Lesher merican Label amp Tag was incorporated in 1988 and is based in Canton Mich The companys original mission was to produce high quality pressur

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