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Automation Notebook: Online Technical Magazine

1. Figure 5 gt ri l Why is grounding important Electronic instrumentation such as PLCs and field I O are typically surrounded by various types of electronic devices and wires T hese electronic devices may include power supplies input output signals from other instru mentation and even devices that are near the instrumentation enclosure All these may present a risk of Electromagnetic Interference EM I or transient interference T his type of interfer ence may cause failure or erratic operation of the device We should consider using a second transformer to source AC power to DC power supplies Input circuits should be utilized to isolate the output circuits and prevent voltage from the output transients spikes from being induced into the input circuits In some cases we may need to use a constant voltage transformer to Stabilize the incoming AC power source supplying the PLC to minimize shutdowns due to power surges voltage dips and brownouts W hen using a constant voltage transformer to power a PLC the sensors connected to the PLC inputs should use the Same power source O therwise the AC source voltage could drop low enough to cause inaccurate input data Also the use of an isolation transformer for example 115 VAC primary to 115 VAC 26 secondary can provide additional suppression of EM from other equipment Isolation transformers should be used near equipment that produces excessive
2. Table 4 H ex to decimal conversions work in much the same way as Binary C 216 would be equal to 19410 12 161 2 16 or 19210 210 A6D 446 would be equal to 42708 10 163 6 162 13 161 4 160 or 409600 15364 2081 440 O ctal Numbers The Octal numbering system is similar to the H exadecimal system in the interpretation of the bits Table 5 T he difference is the maximum value for Octal is 7 since it is a Base 8 For example 63 is equal to 51 6 81 3 80 or 48 7 310 BCD Numbers TheBCD numbering system like O ctal and H exadecimal relies on bit coded data Table 6 It is Base 10 Decimal but it is Binary Coded D ecimal T here sa big difference between BCD and Binary as we will see later One plus of BCD coding is that it reads like a Decimal number whereas 867 BCD would mean 867 Decimal No conversion is needed H owever as with all things computer related there are snags to worry about 000001 I l i Automation Not ebook Fall 2005 Issue Five fk a a a ul mn NE p m7 102 eri a ios al a i a al z p i A a eee Table 6 Real Floating Point Numbers T heterms Real and Floating Point both describe lEEE 754 floating point numbers Most PLCs use a 32 bit format for floating point real numbers Table 7 CC o l mj A 0 Pf E 7 OS s F nm 107 uh F J oiu s af al al y a I Baa gt JT a TO
3. Figure 9 TheBOM can bein theform of a table drawn on one of the sheets along with the schematic and panel layout It can also be done as a spreadsheet which would allow easy indexing and future referencing Wiring Diagram A wiring diagram sometimes referred to as an intercon necting diagram is used mainly for installation by the electrician for routing and terminating the wiring between the various devices and enclosures in the control system Figure 10 is a good example of a wiring diagram Mo ad oT Figure 10 Continued p 28 gt gt 27 Technical Review It should include all control enclosures or cabinets any external devices that are wired into control enclosures junction boxes conduits wireways etc The wiring diagram usually includes conduit sizes distances number of conductors between devices wire sizes colors wire numbers terminal blocks etc T he wiring diagram is also useful for system startup and later for locating wire routing and devices during troubleshooting D esign Tools Although all of the tasks related to documenting the design can be performed with nothing more than a pencil paper and a ruler it is normally more efficient to use a software drafting utility such as AutoD esk s AutoCAD or AutoCAD LT software The biggest advantage in using a software drafting program to create schematics panel layouts bill of materials and wiring diagrams Is the ability to re use the work for
4. Small size saves panel space Made by Eaton Electrical Inc Manufacturer of Cutler Hammer products For more information on our complete line of circuit protection products visit v automationdirect com circuit_protection oa f AA a ER Y eeen WAUTOMATIONDIRECTE E ME l i D a F k A AMO IA A AAA T 1 e he f po ar A e www autormatondirecicom 1 500 633 0105
5. AsaBCD number the value is 4096 If we interpret the converted BCD number as Binary the D ecimal value would be 16534 Similarly if we interpret the Binary number as BCD the D ecimal value would be 1000 Signed vs Unsigned Integers So far we have dealt with unsigned data types only N ow let s talk about signed data types negative numbers BCD repre sentation cannot be used for signed data types In order to signify that anumber Is negative or positive we must assign a bit to it Usually this is the M ost Significant Bit M SB as shown in Table 11 For a 16 bit number this is bit 15 This means that for 16 bit numbers we have a range of 32 767 to 32 767 ea is rajo fefifo e s r 6 aJ fefs ou MSE LSE Table 11 We have two ways of encoding a negative number Two s Complement and M agnitude Plus Sign T he two methods are not compatible As long as the value is positive bit 15 isO FF then the rules work similarly to binary If bit 15 isO N then we must know which encoding method was used The M agnitude Plus Sign is the easiest to decode Basically the negative number isin the same format as the positive number except with bit 15 ON Table 12 0000 0000 0110 0100 1000 0000 0110 0100 Table 12 Decimal Two s Complement is slightly more difficult T he formula is to invert the binary value and add one Table 13 comal mery 0000 0000 0110 0100 100 1111 1111 1001 1100 Table 13
6. ASIS WITHOUT A GUARANTEE OF ANY KIND We do not guarantee that the data is suitable for your particular application nor do we assume any responsibility for them in your application www automationnotebook com 29 The Break Room Humorous stories and Brainteasers WAUTOMATIONDIRECT A Taste of Japan Cultural Observance busiest holiday seasons is an annual celebration held the first week of M ay to celebrate Greenery D ay Constitution Memorial Day and Children s Day M any companies close for several days allowing people to travel sightsee and participate in the festivities We kicked off our event in late April by decorating our main lobby with colorful carp flags and streamers which symbolize strength power and success in life In Japan this is a traditional prac tice of parents to commemorate the health and future success of their sons A Girls Festival is celebrated M arch 3 O ur flags were proudly placed in honor of our Japanese team members From left Mr R Nakamura Executive Director Production and Purchasing Koyo Electronics Mr T Nakayama Director Head of Sales Team Koyo Electronics Mr Tim Hohmann founder and Company Captain AutomationDirect Mr K Nobetani Deputy Director Assistant to Head of Sales Koyo Electronics Mr Y Kohroki Manager Overseas Sales Department Koyo Electronics ecognizing the value and importance of diversity in today s workplace and soc
7. O bviously numbering systems vary and yet are similar It is vital to know which system is being used in order to program the application properly A methodical and logical approach to understanding a given number system being used makes inter preting the data less complex 24 WAUTOMATIONDIRECT Technical Review A Condensed Guide to Automation Control System Specification Design and Installation Part 3 Design by Tom Elavsky AutomationDirect n Part 2 Spring 2005 Issue 4 we covered how to specify the various devices required for interfacing and controlling the electrical equipment in an automated control system In Part 3 we will cover the steps needed to design our auto mated control system The design topics will include planning by defining our sequence of operation creating a schematic with the devices shown in ahigh voltage to low voltage order input to output design layout panel layout wiring diagrams bill of materials software tools to document our design choices between using hard wired relays versus a PLC with programming etc As stated in the previous articles special expertise is gener ally required to design wire install and operate industrial automation control systems Persons without such expertise or guidance should not attempt control systems but should consider seeking the services of a qualified System Integrator Control systems can fail and may result in situations that can
8. article is Industrial Control Panels the scope indicates the article applies to panels intended for general use The new article is not limited to industrial occupancies but rather has general application The term Industrial Control Panel is defined in Section 409 2 as an assembly of a systematic and standard arrangement of two or more compo nents such as motor controllers over load relays fused disconnect switches circuit breakers and related control devices such as pushbutton stations selector switches timers switches control relays and the like with associ ated wiring terminal blocks pilot lights and similar components T he industrial control panel does not include the controlled equipment It should be noted that UL and other electrical testing laboratories have a procedure whereby a panel shop can produce control panels that comply with the UL Indus trial Control Panel safety stan dard As such the control panels are eligible to bear the listing mark of the electrical testing labora tory The internal wiring of these listed control panels is not usually inspected by the local electrical inspector at the time of installation as provided in Section 90 7 ofthe NEC On the other hand the internal wiring of industrial control panels that are built in accor dance with new NEC Article 409 is usually subject to inspection by the local Authority Having Jurisdiction AHJ This is due to th
9. ba call at 1 800 633 0405 or check us out at Software Relays Timers find the articles informative and as Time to Celebrate merce ida e Operator Interface e Communication No part of this publication shall be copied I at feedback Low prices fast shipping and superior service backed by experience e Drives Motors e Terminal Blocks amp 63 reproduced or transmitted in any way always Wel appreciate any ac For over 10 years we ve been committed to treating our customers to an exceptional aes oe petal 5 without the prior written consent of you send our way industrial control buying experience Our team consists of some of the best veterans fromthe A ystems neil Aiea Automationdirect com Incorporated industry giants with field tested knowledge in a wide variety of applications PP Automationd rectretal AS the exclusive rights E i ge gt i pl toall information included in this document mp Batan l l Keri Schieber A Call or go online to request your FREE 1 750 page catalog today M anaging Editor a the 1 valve in automation WAUTO M ATI O N D RECT editor automationnotebook com IE E AN A aes EA p le i l a lt r www automationdirectcam 1 800 633 0405 apy a dds es New Product Focus what s New WAUTOMATIONDIRECT Rhino Series offers vanable DC switching power supplies A utomationD irect now offers the RHINO line of power supplies which includes several new metal and plastic hous
10. color coded to handle the different types of signals that enter and leave our control panel We may choose to use black for high voltage red for inputs violet for outputs etc We should try to locate the terminal blocks so they provide the best wire routing from the components to the terminal blocks The terminal blocks also make it convenient for the electrician to terminate his field wiring when the control enclosure is installed Our design should include the selection of the enclosure that will house our control system We need to consider the envi ronment where the enclosure will be located O utdoors Indoors Wash down required Refer to the section on enclosures in Part 2 of this series of articles for references to N FPA s N ational Electrical Code N EC 2 theN ational Electrical M anufacturer s Association N EM A 4 OSH AP and alist of items to consider when selecting an enclosure Bill of Materials The Bill Of M aterials BOM should list each component in our automated control system the quantity of each component any designations or marks that allow us to easily identify the component on our schematic a description of the component and its part number We also have comments or remarks about the component that will help the panel builder know what needs to be done when the control panel is being built Figure 9 is a short example of a bill of materials Cedo Pri ee AE cara ees AL Pr Mi E A E
11. electrical noise If DC power is required in our control system we need to calculate the worst case amperage draw load of all the devices that will be powered from the DC supply We also need to look at the amount of ripple the devices being powered can tolerate and select a DC power supply that can meet the most stringent requirement Ripple is the amplitude of the AC component that rides on the DC voltage signal A typical rating for most applica tions involving DC powered sensors would be 100 mV peak to peak It is also a good idea to double the calculated amperage capacity of the DC power supply T his is especially important if our control system needs to meet Underwriters Laboratories Inc UL 508A T he next section of our schematic will show the hard wired devices that are powered from our control voltage 115 VAC If our control logic is based on hard wired relays this is where we would show the hard wired connections along with the normal 115 VAC powered devices such as D C power supplies 115 VAC power to PLC power supplies auxiliary devices etc Figure 6 isa partial example of the hard wired section of our schematic mi TOS a al wip q in d dl wre Arne 7 Figure 6 a This is a good point to mention surge suppression Surge suppression devices are an important component in achieving a reliable power distribution system T hese devices protect the elec tronic components from sudden power surges tha
12. for a final decision from DARPA On June 6 DARPA released the names of the 40 teams that made the final cut and Team Buffalo was not among them The Team is disappointed but hasn t given up They plan to continue work on the ANT and unless one of the other teams wins the prize at this year s contest in O ctober Team Buffalo will reenter the contest in 2006 You can follow the Team s hard work and efforts at www TeamBuffalo org Find out more about the DARPA Grand Challenge 2005 at www darpa mil grandchallenge And finally check out more pictures and a video of the ANT at the Automation N otebook weoste www AutomationN otebook com Search for Team Buffalo to see the latest entries oe www automationnotebook com T ig dare or E pushbuttons at great prices so we ve taken advantage of Eaton Cutler Hammer eneen experience to offer you pilot devices that meet those demands The HT800 line of 30 mm metal NEMA devices and the 22 mm non metal IEC E22 series offer you a wide array of pushbuttons selector switches and indicating lights with modular construction that makes on the job installation fast and easy And they re all available at prices well below the competition Call 1 800 633 0405 to request your free 1 750 page catalog or place orders or go online for complete technical details full pricingand convenient ordering Flush extended illuminated or non illuminated mushroom and guarded pushbuttons man
13. fuses contacts and overload relay elements are shown to the left while the symbol for the motor is shown to the right The schematic should start with the incoming power including protective devices such as circuit breakers and or fuses Our design should show the distribution of the AC power and include all circuitry and required devices for conformance to the National Electrical Code NEC 4 and any local codes that might apply in our area www automationnotebook com TE Fil Figure 3 It isnormal practice to show any high voltage devices such as 3 phase motors 480 or 240 VAC auxiliary equipment etc in this first section of the schematic N ext we will show a control power transformer used to step the higher incoming voltage down to our system control voltage 115 VAC O ur control voltage can be something other than 115 VAC for example we could have a control voltage of 24 VDC which is common for many electrical control devices The control transformer needs to be sized VA rating based on our known or calculated load of devices that will be powered from the transformer in our automated control system At this point in our schematic we need to look at device wiring isolation strategies PLCs provide ideal isolation because its circuitry is divided into three main regions separated by isolation boundaries as shown in Figure 4 The PLC s main power supply includes a transformer that provides isolation and the input a
14. future electrical control system designs The drafting software can also be used to create our sequence of operation flowchart or timing diagram Add ins for the various drafting software packages are geared toward electrical control system design T hese add ins contain pre constructed elements of different manufacturers electrical devices This may include schematics of PLC 1 0 modules power supplies communication devices etc T hese pre constructed elements also include scaled outlines of relays motor starters terminal blocks etc that can be dropped into your panel layout design One such add in package that works with AutoCAD and AutoCAD LT for electrical control design and includes some pre constructed elements for various PLC manufacturers is ECT s promise draw software More information on the promise draw can be found at http www automationdirect com static specs pcdrawspecs pdf T his software has the ability to act as a database for components that would be used in our control system design and can aid in coordinating the components between our schematic panel layout and bill of materials Discussion of automation control systems will continue in our next issue with Part 4 Build Install and M aintain Footnotes 1 For Considerations for Choosing a PLC refer to http support automationdirect com docs worksheet_guide_lines html 2 TheNational Fire Protection Association N FPA produces the N ational Elec
15. has an option for connecting an external temperature sensor that adjusts the battery charging voltage automatically to avoid overcharging and increase battery life T he Buffer M odule uses a capacitor bank to store energy and is therefore maintenance free T he hold up time of the Buffer M odule is typically 200ms at 25A and up to 4 seconds at 1 2A Accessories for panel mounting are also avail able for the PSM power supplies New RHINO PSP series power supplies are plastic housed ultracompact switching supplies available in 5V 12V and 24V adjustable models T here are 14 models available with power ratings of 20W to 120W and up to 8A output current They are DIN rail or panel mountable and feature universal 85 264 VAC or 83 375 VDC inputs adjustable D C voltage outputs power good signal and low output ripple along with short circuit overvoltage and overload protection ThePSP models start at 56 for the 24V 1A output model es ec UCCCGCTT RHINO Power products from AutomationDirect MATO TEA LEA T The new RHINO line of power supplies includes metal and plastic housed switching supply models for your control system s DC power needs RHINO PSM metal series switching DC power supplies are available in 12 or 24 VDC adjustable output models al ik Lal a e gt PLE Fi gal a Industrial Metal features Sac tt e Seven models offer power ratings from 78W eee to 600W and up to 25A
16. initially scheduled the visit for May 3 The team respectfully asked for more time and DARPA denied the request Then lo and behold DARPA decided to reschedule the visit for M ay 2 aE a O The Grand Challenge rules stipulate that during the site visit the team will have 3 hours to demonstrate the vehicle T he team is responsible for setting up a 200 meter course with at least two turns Team Buffalo selected a 15 acre site of woods and fields behind several acres of lush lawn in arural area of western N ew York T hey had planned to set up the course in the woods H owever the wooded area was deemed too wet so instead a course was configured on the rain soaked lawn between the road and the woods T he weather did not cooperate before or during the site visit as Schwartz describes in his report T he day started with the weather being just cold and windy H owever before the site visit was over think we had experienced every kind of precipitation known to man rain snow sleet and hail The DARPA officials were patient and encouraging as the team spent 2 1 2 hours troubleshooting a loose pin in the cable connection to the PC With only 30 minutes left in the vist Team Buffalo put the ANT on the starting line crossed their fingers and pushed theGO button M ark describes the moment We quickly moved the vehicle back to the starting line After a brief safety orientation for all we placed the vehicl
17. not be possible to remove the locking means As sited in the NFPA documents T hat was not the intent and there are few if any locking means that are permanent to the point they cannot be removed The original purpose of adding permanently to the Code was to require that a locking means be available at all times i e to prohibit a portable locking means that is removed when the lock is removed Section 430 109 A 6 covers manual motor controllers M anual motor controllers are often a switch that includes a heater element to provide motor overload protection M anual motor controllers are permitted as the motor disconnecting means where marked by the manufacturer as being suitable for that purpose Rules were added on locating the manual motor starter on the line side of the fuses used for running overload protection as permitted in 430 52 C 5 Semiconductor fuses are permitted to be used as branch circuit fuses under 430 52 C 5 H owever they are often used as supplementary fuses to protect electronic equipment and may be located on the load side of listed manual motor controllers marked as Suitable for M otor Disconnect Since as branch circuit fuses they are technically the final motor branch circuit protective device their use downstream from the manual motor controllers violates the Code The change permits the use of these fuses in this location as Supplementary protective devices The manual motor controllers additio
18. output current ae a a E e Steel case to withstand harsh environments eat a 2 e Universal inputs for 115 VAC or 230 VAC CEP e International agency approvals suitable for e A f worldwide use A ry e Low output ripple along with overload and a He ml overtemperature protection e Includes two diagnostic outputs that indicate low output voltage levels to a PLC SCADA or CMMS e Easy wiring for parallel loads using multiple output pluggable screw terminals e Mean Time Between Failure MTBF 350 000 hours IEC61709 25 C e 3 year warranty E RHINO PSP series power supplies are plastic housed ultracompact switching supplies available in 5 12 and 24 VDC adjustable output models Slimline Plastic features e 14 models available with power ratings of 20W to 120W and up to 8A output current PSM Specialty e DIN rail or panel mountable e Low output ripple along with short circuit overvoltage and d overload protection Mo ules e Power good signal e Featuring 85 264 VAC DC universal input e 3 year warranty e Redundancy module e Battery control module e Buffer module For more information visit z www automationdirect com dcpowersupplies aw Check out our prices Power Supplies AutomationDirect 24 VDC Output Plastic Case Allen Bradley Price part number Price part number 277 00 PSP24 060C 60W 2 5A Output 386 00 PSM24 090S 90W 3 75A Output 189 00 PSM24 BFM600S 1606 XLP50E 50W 2 1A Outpu
19. that the disconnection function has succeeded Each of the several point of entry disconnecting means is monitored and opens a magnetic contactor that prevents the mass produc tion industrial machine from being energized The redundantly monitored remotely operated contactor isolating system is always located within the machine s electrical system on the load side of a circuit breaker or fuse A typical redundantly monitored remotely operated contactor isolating system that incorporates control lockout provisions has been reviewed with O SH A the resultant inter pretation is that it can be part of an energy control program and therein a suitable disconnecting means for such purposes Underwriters Laboratories is expected to develop one or more product safety standards for a redundantly monitored remotely operated contactor Isolating system that incorporates control lockout provisions The new Part X of Article 430 covers adjustable speed drives New definitions have been added to 430 2 for adjustable speed drive and adjustable speed drive system This recommended change places requirements for these drive systems in a central location in Article 430 that begins at 430 120 The following list provides an indication of the subjects covered in the new part of Article 430 X Adjustable Speed D rive Systems 430 120 General 430 122 Conductors Minimum Size and Ampacity A Branch Feeder Circuit C onductors B Bypass D evi
20. to drive the electrical contacts open This protects against a potentially unsafe condition should contacts weld A spring action contact does not comply with this requirement e The devices must not be reset automati cally manual reset is a requirement W hy should AutomationD irect customers care about EN 418 Equipment shipped for use within the European Union must meet the require ments of the European M achinery Directive including EN 418 If you ship equipment to Europe the equipment must be in compli ance with the machinery directive If not in compliance your customer risks significant cost impact along with loss of time and potential business because European inspec tors will prevent equipment from being energized until the machinery is made compliant The Eaton Cutler H ammer EN 418 compliant devices offered by AutomationD irect carry all applicable stan dards for application in Europe and North America this enables OEM s to standardize on one device and meet global requirements W hat does AutomationD irect offer AutomationDirect carries the Eaton Cutler Hammer E22 push pull and trigger action twist to release E Stop devices that meet EN418 requirements Part numbers and styles include E22LTA2QB E Stop trigger action maintained 40mm red mushroom pushbutton and E22LPB2B E22 LB2N 8B and E22 PLB2B with 40mm and 50mm push pull maintained mush room operators To ensure acceptance by European machiner
21. value in Circuit Protection and Motor Controls Quality products low prices great selection and same day shipping AUTOMATIONDIRECT now carries a wide range of circuit dr PUJI protection and motor control components for your ELECTRIC electrical systems We offer Fuji Electric s DUO and Odyssey i series motor control solutions with over 250 parts in sizes up to 300 hp at 480 VAC The molded case circuit breakers y and supplementary protectors give you high quality reliable T circuit protection These and all the products shown here are in stock and available for same day shipping at our everyday low prices A sample of parts and pri Basic Contactors a ne A Conte 7 e Load no up to 300hp co MECA a re id 2 to 300 hp T ag Licensed by Eaton Electrical Inc Compact frame sizes from 45 mm RE y Manufacturer of Cutler Hammer up wart m SC E5 100v IEC 105A 110 120vac Dc coil 161 A MCCB P oil S EE RENE technology A sample of parts and prices Circuit Breakers Head to head employed on the larger contactors Pp i ae liability did Starting at 139 Features AUTOMATIONDIRECT SquareD ABB 9 Price Bio 600A ratings A 17328 9 360 2 18 20 587 459 amp FAL34100 S1M100TL 24 VDC 24 VAC 120 VAC and 240 VAC coils S0 E04 110VAC EEE EEE io A Patented contact panel Area mm2 FUJI ai ie Overload Relay 12 18A conductor design lc kA 480
22. 0 years of field experience Brad s repertoire includes designing controls for an automated assembly line at one of the big three automotive manufacturers and designing quality control vision systems for a pharmaceutical giant Team Buffalo was formed in late 2004 and immediately began to design its vehicle and search for sponsors W hiletalking to AutomationD irect about a sponsorship Team Buffalo lined up anumber of other sponsors according to thar Web site By the middle of January 2005 Team Buffalo had comfirmed spon sorships from an engineering software company a local plastics thermoforming outfit and most importantly a catering service yes aie On February 1 Team Buffalo announced that a sponsor ship agreement had been reached with AutomationD irect According to Schwartz Team Buffalo had been in discussions with several other international PLC manufacturers however AutomationD irect was the only PLC manufacturer willing to make a firm commitment and provide a concrete ship date T hey had everything we needed right in stock and were ready 18 to ship overnight Q uality service and availability W hat more could we ask for Schwartz said O n February 9 all requested PLC components were in hand and Team Buffalo began to assemble its control system TheVehicle Team Buffalo decided early on to use an All Terrain Vehicle ATV as its motion platform The combination of low cost and go anywhere design w
23. 2005 ssue Five Feature Story DAR PA update our program to properly record sorted good and sorted bad counts on the fly DirectSoft and NetEdit a networking configurator are excellent tools used by our technicians to trou bleshoot installations and other problems We are also using the DN Loader program to distribute soft ware updates to our customers online and are investigating using Automation Direct s KEPDirect software as an upgrade from D SD ataServer The end result of our work the IMPAX TimeSaver System is a complete production and downtime monitoring system with stand alone monitors and networked real time data collection and display The system is built from of a variety of products that are affordable readily available and reli able In 3 years we ve not had a single hardware failure O ur customers are very happy with the TSS and are equipping many of their shop floor machines with TSS monitors Because we were able to develop the system out of quality building blocks that can be easily procured from a single supplier at affordable prices we were better able to focus on the end result Delivering a product that effectively assists our customers with downtime management needs was a Satisfying achievement to say the least Company Profile Process Technologies Group Inc PTG designs and manufactures process monitors efficiency moni tors and data collection software The IMPA
24. 2005 Issue Five Business Notes A A orrororrrr gt AutomationDirectadds RSS feed service to its Web site Keeping up with the latest industry and automation news can be very difficult with many sources of information vying for attention To help you stay on top AutomationD irect has begun publishing its own RSS feed It s updated any time news such as anew product release updated firmware anew Issue of Automation N otebook or other product information becomes available W hat is RSS RSS Is basically a file format used by Web sites to syndicate news Using free or inexpensive programs called newsreaders or aggregators it is possible to track dozens or even hundreds of Web sites for updatesin a very small amount of time Your newsreader automatically scansthe RSS feeds you specify so you don t have to visit each site indi vidually wondering if anything has changed N ews comes to you on your schedule RSS feeds also called news feeds are all over the Web from major media like the New York Times and the BBC all the way down to individual weblogs and sites Are you already reading RSS feeds Subscribe to AutomationDirect s by putting this link http lists automationdirect com news xml into your news reader To learn more about RSS and newsreaders this Wall Street Journal column is a good place to start http ptech wsj com archive ptech 20050505 html AutomationDirect exhibits a
25. 277V AC ELIET feller ie r with high speed List Price SC E2 110VAC a e i eae T d iti IEC 40A Contactor PLUS Thermal 81 ae ae blow open action b raditiona Overload Relay 32 42A UL4B9 list 225A Breaker ei prince ISUNg Panel Area mm2 Sta rte rs e cias IEC 65A Contactor PLUS Thermal 106 Advanced arc lc KA 480 277V AC Se ore H i Overload Relay 35 65A S u p p eme nta ry extinguishing List Price by wn a Contactor technology Sai ri re U S list prices AutomationDirect prices are from March 2005 Square D pri re from Pricing Guid ove iaa Protectors ios a Thermal overload relays Manual Motor Starters One pole models 7 50 Molded Case Circuit Breakers Technical Specifications Can be used with 1 2 to 300hp Price Two pole models 15 E T W u l tler Hammer i i gog a i Overload open phase Manual Motor Starter 10A FLA W C 375B __AC kA __ DC kA protection UL 1077 recognized A a oro Ambienttemperature IO TEEN E 6 to 60 amp ratings MON ESTO MECO IO E ES EA META ECO compensation overload trip rating Current limiting design for fast short F Frame 100 225 3 f 22a 65 35 18 to 319 BM3VHB 050 Manual Motor Siarter 30A PLA 138 circuit protection K Frame j 250 400 3 f 23a 65 35 25 10 599 overload trip rating iFrame 000 a 2a s 2 799 __ a mbination rter ELECTRIC Combination starters Motor Controls Head to head C
26. Advanced Research www automationnotebook com Projects Agency DARPA is the central research and development organization for the United States Department of D efense DoD DARPA s mission is to manage and direct selected basic and applied research and development proj ects for the DoD and pursue research and technology where risk and payoff are both very high and where success may provide dramatic advances for traditional military roles and missions DARPA was founded in response to the surprise Sputnik launch in 1958 and it s been Uncle Sam s hope that DARPA would helo the U S avoid technological From Left Brad and Mark of Team Buffalo surprises created by other countries sincethen Among other notable achieve ments DARPA even helped to father the Internet along the way T hisisthe second time D ARPA has held the Grand Challenge In 2004 none of the 15 teams entered was able to complete the course successfully Some entries failed spectacularly and others failed on the starting line making no progress whatsoever The two most successful teams managed to travel just 7 of the 142 prescribed miles The stated purpose of the Grand Challenge is to accelerate develooment of autonomous vehicle technologies that will save lives on the battlefield Although there was no winner at the Grand Challenge 2004 DARPA obtained a number of important ideas that may lead to Continued p 18 gt gt 15 The best
27. C or 24 VDC Several other combinations are possible in N orth America and other countries and are easily derived from the methods shown in this document The motor starter must have at least two components to operate a contactor to open or close the flow of energy to the motor and an overload relay to protect the motor against thermal overload Other devices for disconnecting and short circuit protection may be needed typically a circuit breaker or fuses Short circuit protection will not be shown in the examples that follow The contactor is a 3 pole electromechanical switch whose contacts are closed by applying voltage to a coil When the coil is energized the contacts are closed and remain closed until the coil is deenergized The contactor is specifically designed for motor control but can be used for other purposes such as resistive and lighting loads Since a motor has induc tance the breaking of the current is more difficult so the contactor has both a horse power and current rating that needs to be adhered to T he overload relay is a device that has three current sensing elements and protects the motor from an overcurrent Each phase going from the contactor to the motor passes through an overload relay current sensing element T he overload relay has a selectable Automation Not ebook Fall 2005 Issue Five current setting based on the full load amp rating of the motor If the overlo
28. L05 06 The100M b models provide support for TCP IP UD P IP IPX and MODBUSTCP IP protocols Additionally wireless communications is also gaining popularity particularly in applications where distance and wiring expense make it a cost effective alternative to wired systems For detailed articles on wireless communications see the Winter 2005 issue of Automation Notebook or visit www automationnotebook com AutomationD Irect s Ethernet modules and serial port modules work well with the Cirronet line of serial and Ethernet radio modems that AutomationD irect now offers T he Unchanged Amidst continuous change one facet of the PLC that remains true to form is the programming language Approximately 95 percent of those surveyed still use ladder diagrams to construct their PLC code Although many languages are now available it seems that ladder logic still continues to bea top choice given it s performed so well for so long So what s in store for the future Let me consult the M agic 8 ball about this mystery asking the question Will there be change For once get a crystal clear answer WITHOUT A DOUBT So buckle up and hang on it s going to be a wild ride sm We live in a moment of history where change is so speeded up that we begin to see the present only when it Is already disappearing R D Laing a Goings On in the Automation ndustry e s ec es e 3 Automation Notebook Fall
29. N UDK2120 Power Supply NEMA 34 Stepper Motor STP MTR 34066 A complete 2 axis SureStep Stepping System for less than just the 2 484 772 z competition s stepping drives for 2dri 3 i Operates atleast two p pping we 493 for 2 drives or 2 drives stepping systems of o Si SureStep Complete NEMA Ours includes 2Ax S System any alae 23 System Pen y e Two Microstepping Drives Stepper Motor Auxiliary 5 VDC Long Stack 2 Stepper Motors STP NTR 23079 r Une rower ou Power Supply supply i Cables i STP PWR 3204 All prices are U S list prices AutomationDirect prices are June 2005 Oriental Motor prices are from shop orientalmotor com om servlet site3003 as of 7 27 04 Pacific Scientific prices are from Kim Controls Distributor as of 3 15 04 All product names trademarks and registered trademarks are the property of their respective manufacturers AutomationDirect disclaims any proprietary interest in the marks and names of others For more information visit www automationdirect com stepper_ systems tres vale in autormi ee A WAUTOMATIONDIRECT q wenw automationdirect com 1 800 633 0405 ta Whether you prefer fuses circuit breakers or other types of protectors AutomationDirect carries a full selection of devices at incredible prices We ve partnered with Edison Fuse a subsidiary of Cooper Industries to offer fuses and accessories that can be cross referenced to other name brand
30. O o O Table 7 T he formula and layout of the number is as follows N umber 1 M 2 E 127 N umber the number to be converted to floating point M M antissa E Exponent Calculating the Real number format is a very complex oper ation If you are interested in the conversion process there are numerous documents on the Internet that go into specific detail You may have noticed that there is not a minimum or maximum value given for the Real number format T he range is from negative infinity to positive infinity H aving said this and having noticed that there are only 32 bits possible to create every number it is easy to surmise that not all numbers can be repre sented This isin fact the case T here is an inherent extent of error with the Real format I m sure you re wondering how much error can exist and if there is alot of error why is this format used It really depends on the application For most PLC applications unless you are aiming for 100 accuracy the Real format will not pose many problems M ost of the time the inherent error can beignored but it is impor tant to know it exists BD C Binary D ecimal H ex O ctal W hat is the D ifference Sometimes there is confusion about the differences between the data types used in a PLC The PLC s native data format is BCD while the I O numbering system is Octal Other numbering formats used are Binary and Real Although data is stored in the same manner 0 s and 1
31. Prices subject to change without notice AuTOMATIONDIRECT disclaims any proprietary interest in the marks and names of others Manual ON OFF control with lockout capability Trip free design e SD1 series disconnects loads at 5 p nominal current range of 16 40A Bo a SD2 series disconnects loads at nominal current range of 63 125A Visit www automationdirect com motorcontrols for more information on our complete line of motor control products 1 800 633 0405 YAUTOMATIONDIRECTE Feature Story WAUTOMATIONDIRECT promising developments and is certain that important research progress will also be made leading up to the 2005 event regardless of the outcome The Team Team Buffalo is a two man partnership lead by M ark Schwartz a software engineer and a licensed master electrician specializing in systems integration process controls and automa tion He has over 20 years of experience designing and developing automation systems Past projects include an emergency shutdown system designed for a multi national chemical producer and a satellite based automatic dispatch system implemented for a national utility company Schwartz has extensive software experience at both the embedded and applications levels and enjoys developing practical solutions to real world problems Joining Mark is Team Manager and Senior Engineer Brad Burzynski Brad isaPLC programme systems Integrator and electrical engineer with over 1
32. Systems Communications Power Supplies and Protectors Relays Process Controllers Name Company Address Endusr OEM Othe Type of Business Integrator Fax your request to 770 844 4212 www automationnotebook com Cover Story Electrical Code WAUTOMATIONDIRECT 2005 NEC ode Changes by Phil Simmons Guest Writer he purpose of the National Electrical Code N EC is the practical safeguarding of persons and property from hazards caused by using electricity The NEC is prepared by a committee made up of a Technical Correlating Committee and 19 code making panels The committee s responsibility is to create documents specifying code which when adhered to minimizes the risks of electricity as a source of electric shock and as a potential ignition source for fires and explosions Published by the National Fire Protection Association the NEC is updated every three years Significant changes in the 2005 edition that we will be discussing are the new Article 409 and changes made to existing Article 430 Industrial Control Panel Article 409 Article 409 covers industrial control panels intended for general use and operating at 600V or less A fine print note references Underwriters Laboratories UL 508A as the safety 8 standard for industrial control panels Extensive substantiation was provided with the proposal for each of the new requirements While the title of the
33. W here adherence to extensive current limiting codes is not The HO ECOM 100 can actively issue MODBUS commands to other nodes or devices on the MODBUS TCP IP network or simply respond to connected MODBUSTCP IP clients Link your PLCs with PCs using industry standard MODBUS TCP IP protocol connected through standard cables hubs and repeaters Or use our KEPDirect I O Server to link to your favorite HMI SCADA data historian M ES or ERP software to DirectLO GIC PLCs Our LookoutDirect HM and DataWorx data collection software includeECOM drivers DirectSO FT 32 Programming Software can be used to monitor or update the program in any DirectLO GIC PLC on thenetwork Free N etEdit3 Software ships with the ECOM Module User M anual to be used for setting up the ECOM modules for your network required the Class M general purpose midget fuses provide an effective solu tion for both time delay and fast acting protection Primary among the applica tions for the Midget class are supple mental protection of end use equipment as well as small motors transformers solenoids and other high inrush power circuits All fuses are compact in size and offered in boxes of 10 at prices ranging from 7 to 50 per box Also available are companion DIN rail mount fuse holders and panel mount fuse blocks Ethernet Communication Module HO ECOM 100 Cumming GA June 1 2005 Recently added to Automation Direct s
34. Wane oe A PA AAA ee ee nani ae Arata ee oe a 7 re i i a ee E io ee oe BALE ET car fle Pegs rl OE OA oe oe LA eet F C ET i PP l L i Lar roi call 2 2005 Cover Story 2005 NEC Changes BURSRUBEUEU New Prod net Focus Rhino Power Supplies Technology Brief EN4 18 Directive Feature Story 2005 DARPA Grand Challenge UU Aut omation Not ebook Fall 2005 ssue Five Automation NOTEBOOK Your guide to practical products technologies and applications Contnbutors Editors Note Table of Contents Publisher TinaCrowe Summer is winding down the New Product Focus 4 oo kids are back in school and if you ve Rhino Power Supplies ManagingEditor Keri Schieber been distracted by vacations and sunny The 1 Value i in tonto cuniarediae anda weekends you re probably thinkingit s Product Snapshots 6 entorkditor Linda Lonegan DataNet OPC Edison Fuses ma y time to get your mind back on work H0 EC M100 i Design Manager Justin Stegall At AutomationD irect we ve had g 2001 Voted 1 service by independent survey EES uini air ande masdan lara Cover Story 8 Control Design magazine s Readers Choice Awards 2001 oon Sere Early summer saw some of us moving 2005 NEC Code Changes best service of any supplier for PLC Hardware and PLC Software Phil Simmons at last into the building next door It PLC Speaking 1 Jeff Payne took longer than antici
35. X TimeSaver System is the company s machine efficiency and downtime tracking system PTG can be reached at 1 800 272 4784 or at www impaxptg com 2005 DARPA Grand Challenge by Chip McDaniel AutomationDirect AA df fte preliminary testing of our vehicle and the subsequent breaking of a couple of we ds weve come to a few conclu gons First our teing actuator has a lot more power than wereally need Second we never should have attempted to tet the ering syten without the use of the encoder feedback And third wereally ned to add a couple of over trave limit switchesto the ering ystem This excerpt is just one sample amp of various e mails M exchanged by AutomationD irect and Team Buffalo over the last several months Team Buffalo is a pair of engi neers from Buffalo N Y who constructed an entry for the 2005 DARPA Grand Challenge The Challenge D ARPA Grand Challenge 2005 isa field test of robotic ground vehicles for the purpose of advancing autonomous vehicle technology The vehicles must travel approximately 150 miles over rugged desert roads using only onboard sensors and navigation equipment to find and follow a designated route while avoiding obstacles After the O ctober 8 2005 event DARPA will award 2 million to the team whose autonomous vehicle successfully completes the route the fastest within a 10 hour period All vehicles must be developed without government funding The Defense
36. ad current exceeds the setting of the relay for a suffi cient length of time a set of contacts opens to protect the motor from damage T his article shows how to wire various motors using the FUJI series of contactors sold by AutomationD irect Other brands of contactors may be wired the same or simi larly Consult the manufacturer s wiring diagrams for other brands of contactors There are four basic combinations wiring a Full voltage non reversing 3 phase motors b Full voltage reversing 3 phase motors c Single phase motors d Wye delta open transition 3 phase motors You must supply a disconnect switch proper sized wire enclosures terminal blocks and any other devices needed to complete your circuit WARNING Use the Instructions supplied for each specific device Failure to do so may result in electrical shock or damage The following components will be used Eo a Contactors Overload Relays Aux Contacts e H Mech Norm Open Norm Closed 24 VDC Interlock Pushbutton Pushbutton Power Supply Full vol non reversing 3 phase motors The following diagram depicts 3 phase non reversing motor control with 24 VDC control voltage and manual operation We will use a contactor an auxiliary contact block an overload relay a normally open start pushbutton a normally closed stop pushbutton and a power supply with a fuse The start and stop circuits can also be controlled using PLC input
37. advantage of using Excel is access to all of its charting and graphing features In addition we can perform automatic calculations and display relevant data via Excel macros The overall configuration is depicted below Machine weith Sensors Computer Computer Computer Milih Excel With Excel Ath Excel S0MWare Sofware S0MMtare IMPAX TSS System Block Diagram In developing the sys tem problems were encountered that required extensive program ming and debugging efforts along with resolution of hardware configuration issues Each hurdle was overcome with determined troubleshooting and the aid of AutomationD irect s responsive technical support staff who helped us solve some quirky networking glitches Consequently today we have a very solid system The TSS production monitoring system is ready to install for most applications but can also be customized for a particular application Using AutomationD irect parts soft ware and tools provides lots of options With the PLC programming software on a laptop we can make modifica tions for a customer right on their shop floor For example one of our customer s machines sorts and counts parts Using the DirectSoft software and EZTouch editor we were able to i bi Bme eon m T E Ak E la e P m i Lt E rs a mm ail E 2 Ak E mu e a rs mo ce l A a Er mrm ae I MT diii Automaton Notebook Fall
38. better suited to using a timing chart in which each condition and event is graphed in a time relationship to each other as shown in Figure 2 Once we have a sequence of operation developed and a list of our input and output devices we can deter mine if our automated control system is best suited for hard wired relay logic or can benefit from a PLC 1 A PLC can be cost effec tive when used in place of only a half dozen industrial relays and a couple electronic timers It adds the flexibility of making future logic changes without the labor of making wiring changes Figure 1 TEAM BETO Pusher oaualed Ciara HSM mi Part in Poston Ened Tirer 2 anni Pral Mid Figure 2 ime Schematic The next step in our design isto develop a schematic M ost electrical designers and engineers define a schematic as a drawing that shows the logical wiring of an automated control system A control schematic is normally drawn in the form of a ladder showing the various wiring conditions T his analogy of a ladder is what PLC ladder logic was based upon It made the transition to PLC ladder logic easier for engineers and electricians because they were accustomed to trouble shooting hard wired relay control systems shown in a ladder fashion It is normal practice as shown in Figure 3 to show input type devices on the left hand side of drawings and output devices on the right hand side For example the symbols for protective devices
39. cause serious injury to personnel or damage to equipment T he information provided in this series of articles is provided as is without a guarantee D esign The design for our control system will be in the form of a documenting task The challenge will be to get our design specifics down on paper so that it can be easily understood It isimportant that anyone can look at our documents in the future and be able to interpret the information Useful to us at this step will be any notes and lists that were developed during the Identifying and Specifying phases of our automated control system Sequence of O peration In most cases the first step in designing our control system will beto define the process or actions to take place by way of a sequence of operations description T he sequence should show or list each operational step in our process Our particular application may be better suited to using a flowchart that shows the sequence of operation by means of deci sion making steps and actions that need to take place Figure 1 shows a partial example of a flowchart A flowchart can be developed with graph paper and a pencil or an application software program such as MicroSoft Visio M icroSoft s Word software program has a built in drawing tool nomen TEE 200050 T PEILIT Aut omation Notebook Fall 2005 ssue Five that contains flowchart symbols In some cases the application may be
40. ce 430 124 O verload Protection A Included in Power Conversion Equipment B Bypass Circuits C Multiple M otor Applications 430 126 M otor O vertemperature Protection 10 NEC and NFPA are Copyright 2005 National Fire Protection Association NFPA Quincy MA All rights reserved A General B Motors with Cooling Systems C Multiple M otor Applications D Automatic Restarting and Orderly Shutdown 430 128 D isconnecting M eans Adjustable speed drives The substantiation for the proposal stated adjustable speed drive systems has gained enormous popularity over the last few years but appropriate installation rules need to be addressed A companion proposal was accepted to add definitions to Section 430 2 of two terms pertaining to drive systems Asa result of this new part of Article 430 previous parts were renumbered as were several sections and tables that follow new Part X Part XIV now covers motor full load current tables and begins with Table 430 247 rather than Table 430 147 Conclusion W hile we have reviewed the most significant changes made to Article 430 and new Article 409 several hundred additional changes were made in thenew 2005 NEC O bviously some changes are more significant than others In addition NFPA has published a scheduleto producethe 2008 NEC The schedule shows a closing date of Nov 4 2005 for receipt of proposals to change the 2005 NEC Phil is self employ
41. d has designed anew machine for the factory where he works His design was followed perfectly but he forgot to specify the order and the labels for four light switches on the control console T hese four on off switches are wired to four ordinary light bulbs on the far end of the machine out of sight from the control panel He knows that each switch is correctly wired to one of the lights He knows that all the bulbs are new and working and he even knows the on and off position of the switches but he doesnt know which light is connected to each switch Fred s bossis on the way out to the factory floor to see a demonstration of the machine but Fred must determine how the switches and lights are wired before he can give a successful demon stration He only has time for one trip down to the far end of the machine where the lights are mounted H ow can Fred determine which switch controls each light in a single trip without anyone to help him Please visit www automationnotebook com for answers to brainteasers SureStep for Motion Control The SureStep open loop stepping system includes a high performance microstepping drive linear power supply and high torque motors Microstepping Drive STP DRV 4035 One size fits all microstepping drive e Selectable step sizes of 400 steps per revolution 2 1 000 5 2 000 10 and 10 000 steps per revolution 50 e One standard microstepping drive ope
42. e multiple output terminals to facilitate wiring in parallel load configurations dual status indicator LEDs and a pluggable screw terminal block for quick installation and removal Prices for PSM models start at 86 for the 24V 3 75A model The PSM power supplies comply with the latest EM C immunity and emissions standards for industrial environ ments T here is also a model in this series that complies with NEC Class 2 safety requirements The M ean Time Between Failure M T BF reliability is greater than 350 000 hours in accordance with the IEC 61709 standard Innovative add on modules for the RHINO PSM line include a Redundancy M odule for configuring a true redundant power system with power sharing a Battery Controller Module suitable for creating aD C Uninterruptible Power Supply UPS system by charging and monitoring an external battery and a Buffer M odule for maintaining output voltages of a 24 VDC power supply after brownouts or voltage dips The Redundancy M odule can connect two RHINO PSM power supplies to provide fully redundant output power and includes an alarm output signal when one of the power supplies has failed or has been disconnected T he Redundancy M odule inputs are hot swappable for uninterrupted maintenance and can be loaded up to 15A each For configuring a DC UPS the Battery Controller M odule provides a battery management system for charging and monitoring a lead acid battery The Battery Controller module also
43. e back into Auto mode and steoped back to wait for our hard coded time delay to kick in before the vehicle moved Shortly after the mandatory 5 second audible alarm horn sounded the vehicle gradually accelerated down the course At first everything looked great But then all of a sudden for no apparent reason the vehicle stopped abruptly As we watched anxiously we could see the linear actuators on the transmission shift the vehicle into reverse Brad and looked at each other with stunned faces We knew the vehicle s onboard collision avoidance system had just kicked in but neither of us knew why Once the actuators stopped the vehicle started to move again but of course it was going in reverse We had hoped it would travel just a short distance in reverse We assumed that once it cleared whatever obstacle it thought was there it would automatically shift itself back into forward gear U nfortunately it continued In reverse running over one of the orange safety cones on the left lateral boundary and headed off toward the woods Unfortunately for Team Buffalo the renaining attenpts proved to be equally disappointing Weather conditions grew noticeably worse with driving hail and sleet that made troubleshooting almost impossible In the end they were unable to successfully navigatethe course buttheD ARPA officials were still encouraging and very interested in the venicle and design approach The Team was left to wait until June
44. e field assembled control panels not being listed by a qual ified electrical testing laboratory but being assembled in accordance with N EC rules If the AH determines the control equipment being field assembled is an Industrial Control Panel compliance with all conditions of Article 409 is required including the extensive marking specification in 409 110 The NEC offers no explanation for the term systematic and standard arrangement of two or more components as included in the definition in 409 2 T he question is raised since industrial control panels are often oneof a kind designed to control a specific operation rather than being mass produced Rules are provided in 409 20 on sizing a supply conductor to the indus trial control panel T hese conductors will often meet the definition of a feeder conductor in the NEC Article 100 In this application a feeder conductor is a set of conductors that usually has overcurrent protection on the supply side and terminates at equip ment where branch circuits originate T he supply conductors to the industrial control equipment must be no smaller than 125 percent of the full load current rating of all resistance heating loads plus 125 percent of the full load current rating of the largest motor plus the full load current of all other motors and apparatus supplied An adjustment can be made based on the duty cycle of the equipment See 430 22 E for the appli cation of multipli
45. ed as Simmons Electrical Services Services include consulting on the National Electrical Code and other Codes writing editing illustrating and producing technical publications and training materials presenting attechnical seminars and other training sessions and inspection of complex electrical installations He also provides plan review of electrical construction documents Phil presently serves NFPA on Code Making Panel 5 of the National Electrical Code Committee grounding and bonding He previously served on the NEC CMP 1 Articles 90 100 and 110 as Chair of CMP 19 articles on agricultural buildings and mobile and manufac tured buildings and member of CMP 17 health care facilities He served six years on the NFPA Standards Council as NFPA Electrical Section President and on the NEC Technical Correlating Committee www automationnotebook com Stay Current with a DELALAA LES AIP Introducing Electrical Grounding and Bonding By J Phil Simmons GROUNDING BONDING HASED ON THE 2005 NATIONAL ELECTRICAL CODE l Philip Simmons Written in accordance with the 2005 NEC this new book provides readers with a comprehensive introduction to the essential elements of electrical grounding and bonding Using straighttorward easy to understand explanations it examines the critical concepts of calculating conductor sizes reading and interpreting NEC tables the use of grounded conductor connect
46. ed switching supply models Thenew RHINO PSM series power supplies are indus trial grade switching DC output supplies with a sturdy steel case to withstand harsh environments Autoselect inputs for 115 VAC or 230 VAC and international agency approvals make the RHINO PSM series suitable for worldwide use RHINO PSM power supplies are available in 12 or 24 VDC output with adjustable output voltages and feature low output ripple along with overload and overtemperature protection T he seven models offer power ratings from 78W to 600W and up to 25A output current Each power supply includes two diagnostic discrete outputs for monitoring low output voltage levels allowing for remote notification to a PLC SCADA or Maintenance M anagement System One output is a transistor device that can be directly connected to the logic input of an I O device such as a PLC for remote monitoring and annunciation of low voltage levels T he other output is a relay output that can be connected to any dry contact capable device and will open its contact when the output voltage drops Additionally each PSM unit can be 4 configured for Remote ON OFF activation by wiring the Remote ON OFF terminal in series with a relay or 1 0 device and the Vout terminal T his allows any logic device PLC or remote I O node to activate or deactivate the power supply output power for easy system startup shutdown or mainte nance purposes RHINO PSM power supplies also includ
47. ehicle procured sponsorships lined up and a control system design in hand Team Buffalo worked day and night seven days a week to modify the ATV fabricate the control system and program the PC and PLC As part of the formal application process to DARPA the team was required to submit a 5 minute video detailing and demonstrating the vehicle by M arch 11 T here were some hurdles as Schwartz explains At first we had some minor difficulty programming the analog inputs and outputs on the DL205 PLC H owever one quick call to AutomationD irect s support line and we were back on track in no time at all In fact was truly amazed at how fast we were able to get through to a Knowledgeable support engineer We had the answers and information needed to configure the analog inputs and outputs in less time than we typically soend on hold with some of the other PLC manufacturers As detailed in the opening email excerpt Team Buffalo also learned a hard lesson about encoder feedback and limit switches for servo systems but were up to that challenge as well T he two soon announced that they were one of 136 teams that had successfully completed the application process Automation Not ebook Fall 2005 ssue Five The Team continued working feverishly to complete and refine their design On April 11 they were notified by DARPA that a formal site visit was being planned by the D ARPA officials during the month of M ay DARPA
48. ent years but has just about reached its physical limits Nanotechnology promises to take the process much further In the September 2003 issue of IEEE Spectrum it was reported that the Samsung Group in Seoul South Korea had demonstrated a full color 38 inch display using carbon nanotubes that can handle normal video frame rates Such a display promises higher resolution better image quality and more efficient operation than the best liquid crystal display or plasma screens on the market today Applications in other industries include The Gap clothing store which in 2003 began selling pants impregnated with a new stain resistant chemical developed with nanotechnology For abasic description of nanotechnology and its possible uses see http science howstuffworks com nanotech nology htm For more detailed information on the science and its progress visit www leee org and search on nanotechnology The one serious conviction that a man should have ts that nothing isto be taken too seriously Nicholas Butler 1862 1947 13 User Solutions Time Saver System WAUTOMATIONDIRECT Downtime Monitoring With PLC Technology by Steven Noto Guest Writer hen our company set out to design a basic system for monitoring downtime on customers factory machines we were new to using PLCs and related technology Four years later by incorporating products from AutomationD irect we are now able to offer ou
49. ere compelling attributes M odifications to enable autonomous control and the guidance system were begun only after an extensive test driving and break in period Burzynski was eager to gain in depth knowledge of the vehicle s handling capabilities He said I need to know the vehicle s limitations and handling characteristics so can program the PLC to those limitations T he vehicle was dubbed the AN T Autonomous N on M anned Transport Team Buffalo s approach to the navigation and control system was fairly straightforward a pair of commercially avail able GPS systems that acquire position data and a heading direction of travel from geo synchronous satellites T his navi gational information is transferred to a Pentium class single board computer via an RS 232 serial link The PC is used to preprocess and filter the navigational information before sending it to an AutomationD irect D L205 PLC ThePLC controls servo actuators for steering and throttle control and a linear actuator for shifting the transmission The PLC also accepts inputs from seven ultrasonic obstacle avoidance sensors and plots the actual course of the ANT To quote Schwartz In essence the single board computer tells the PLC where we are now where we want to go and our current heading T hePLC then uses that information along with the obstacle and collision avoidance information to steer the vehicletoward our desired destination Qualifying With a v
50. ers for motors that Operate under a duty cycle concept Overcurrent protection of field assembled industrial control panels must comply with the requirements of Article 240 Parts Il and IX Part includes the general rules for overcurrent protection Pat Il provides requirements on the location of overcur rent protection and Part IX provides rules on overcurrent protection for over 600V nominal Automation Not ebook Fall 2005 ssue Five Disconnecting means for industrial control panels that supply motor loads must meet rules for discon necting motor controllers in Article 430 Part X T his generally requires a discon necting means on the supply side of the controller and within sight of the controller defined in Article 100 as visible from and not more than 50 feet away Requirements for grounding industrial control panels must generally comply with Article 250 Specific requirements are provided in 409 60 Construction requirements for industrial control panels are found in Part Ill of Article 409 Rules are provided for enclosures installing busbars and conductors wiring space and for where the control panel can be used as service entrance equipment Extensive marking requirements are contained in 409 110 including the short circuit current rating of the assembly A fine print note refers to UL 508A 2001 where an approved method for determining the short circuit current rating can be fou
51. fuses Choosefrom the most popular 13 32 x 1 1 2 size CurrentLimiting Class CC and the Class M Midget general purpose fuses for industrial control applications 600 VAC rated current limiting fuses available from 0 25 to 30 amps 250 500 and 600 VAC rated general purpose fuses some up to 50 amps Available in time delay and fast acting models Fuse holders and fuse blocks available in 1 2 and 3 pole models for convenient fuse installation and replacement re Check out our prices Fuses AutomationDirect Price part number Price part number l ma get CI ass M fast acting 3 20 tes 10 50 Class CC current limiting time delay 4 30 ses 11 09 D Midget Class M time delay 1 40 ses 3 89 6 ul dass CC cu rrent limiting time delay 4 10 es 13 21 8 All prices are US list prices AutomationDirect prices are from Volume 10 June 2005 Prices and specifications may vary by dealer Littelfuse prices are from http www newark com 4 28 05 All product names trademarks and registered trademarks not owned by AutomationDirectare the property of their respective manufacturers AutomationDirect disclaims any proprietary interest in the marks and names of others Prices subject to change without notice e Available in G F K and L frame sizes from 15 to 600 Amps Patented contact conductor design with high speed blow open action UL489 listing e Advanced arc extinguishing technology
52. iety in general AutomationDirect has chosen to periodically soonsor programs that endorse continued awareness of different cultures In early May we hosted A Taste of Japan an educational and food sampling event to coincide with the Golden Week season in Japan Since our parent company is Koyo Electronics see image above learning more about Japanese customs was appropriate and mean ingful All teamers enthusiastically participated some even sporting tradi tional Japanese attire Golden Week one of Japan s three 30 As we tasted authentic Japanese foods prepared by Mr Ono our guest sushi chef volunteers from the Atlanta Japanese Cultural Center introduced us to culture art clothing and other tradi tions Many thanks to our Japanese team members and their families for the success of A Taste of Japan at AutomationD irect AAA AA Brainteasers 1 Walking in Circles A classic puzzle describes the hunter who walks a mile south turns and walks a mile east turns again and walks a mile north He is surprised to find himself right back where he started H ethen shoots a bear W hat color isthe bear The answer is usually given as white because the hunter must have started his 3 mile walk at the North Pole Can you find some other places on the globe where you could follow those same directions and end up at your starting point Hint No polar bears near any of those places 2 Out of Sight Fre
53. ion 430 102 B provides the location requirements for the discon necting means for motors T his section has been the subject of much discussion over recent NEC editions Changes were made to the rule on disconnecting means being located within sight of the motor and driven machinery The second sentence of B in the 2002 NEC requirement is deleted and a phrase in the exception has also been deleted The NEC Code Panel made orga nizational and substantive changes to the main text and exception T he second sentence of the opening paragraph is moved to follow the fine print notes so the exception does not now modify the previous second sentence N ow clearly the disconnecting means on the supply side of the motor controller is permitted to be the only disconnecting means for the controller and motor if it is within sight of both Continued p 10 gt gt Cover Story Electrical Code QOontinued WAUTOMATIONDIRECT The Code Panel stated the word perma nently in the exception as related to the method for lock ing the discon necting means It was deleted Disconnects with provision for adding lock because it was considered confusing The intent of this change in the 2002 NEC was to require the provisions for locking always to be in place and not to be removed when the lock is removed Permanently was used to convey this concept but some inter pretations have been that permanently means it shall
54. ions in DC and AC systems as well as various installations and sizing 384 Pages 81 2 211 softcover 4 Color List 52 95 Order 1 4018 5938 0 FELTRAMCES wwe delmarelectric com TO PLACE AN ORDER CALL 1 800 347 7707 PLC Speaking Let s talk PLG WAUTOMATIONDIRECT The Evolutionary PLC Past Present and Future by Jeff Payne AutomationDirect Product Manager PLC 1 0 and PC Controls Group E veryone knows there s only one constant in the tech nology world and that s change inevitable change This is highly evident in the evolution of PLCs and their varied applications Let s take a look at yesterday s focus and more importantly today s and beyond Preparing and equipping users to meet the challenges of technological change head on is always a priority at AutomationD irect The most recent PLC Product Focus Study from Reed Research Group shows that not only are applications changing but also the factors important to the users machine builders and those making the purchasing decisions H ere s a snapshot Process batch control has now surpassed machine control as the most popular application for micro to medium PLC applications lt 512 1 0 Communications and processing skills of the micro PLC 15 128 I O continue to improve to the extent they exhibit the same capability in controlling process systems as their larger counterparts M otion control and batch control continue
55. line of Ethernet communica tion products is the HO ECOM 100 module Ethernet communication mod ules reoresent a price breakthrough for high speed peer to peer networking of PLCs No longer are you forced to designate a single PLC to be the network master Any PLC can initiate communications with any other PLC The H0 ECOM 100 supports the industry standard MODBUS TCP IP Client Server protocol in addition to the standard IP and IPX protocols This allows a DLO5 or DLO6 PLC with an H0 ECOM 100 module to serve as a client master or as a server slave on a MODBUS TCP IP Ethernet network You see wire telegraph is a kind of a very very long cat You pull his tail in N ew York and his head is meowing in Los Angeles Do you understand this And radio operates exactly the same way you send signals here they receive them there T he only difference is that there is no cat Albert Einstein when asked to describe radio US German born physicist 1879 1955 es E 9 gt Fall 2005 ssue Five Request your NEW FREE 1 750 page Catalog Buy directand getlow everyday prices on Industrial controls Get your FREE 1 50 page catalog with over 5 500 high quality industrial automation components with helpful selection guides specifications and full price list PLCs Operator Interfaces AC Drives and Motors Sensors e Motor Controls Pushbuttons and Lights Enclosures Connection
56. nally marked Suitable as Motor Disconnect will be suitably protected by the branch circuit protective devices located on their line side Section 430 109 A 7 lists rules for installing system isolation equipment System Isolation Equipment is defined in Section 430 2 as a redundantly monitored remotely oper ated contactor isolating system packaged to provide the disconnection isolation function capable of verifiable opera tion from multiple remote locations by means of lockout switches each having the capability of being padlocked in the OFF open position T he concept of system isolation equip ment provides lockout capabilities in the motor control circuit rather than in the power circuit Thischangeto Article 430 was intended to align with the latest edition of NFPA 79 the Standard for Industrial Machinery Specifically it refers to Section 5 5 Devices for Disconnecting Isolating Electrical Equipment paragraph 5 54 3 This type of equipment is principally intended for industrial machines covered by NFPA 79 where because of multiple entry points or high frequency usage the use of other isolation devices becomes impracticable Because of size manufacturing machines often have several entry points used by operators and maintenance personnel who cannot always see one another W ith a moni tored safety lockout system each point of entry has a lockout capable disconnecting means and a method to verify to the user
57. nd Rules in other standards might apply to specific control panels such as NFPA 79 for industrial machinery Article 430 Several changes to Article 430 were made for the 2005 NEC This includes some reorganization renumbering and inclusion of a new Part X on adjustable speed drives Motor Controller Section 430 8 covers marking on motor controllers M otor controllers are now required to be marked with the short circuit current rating Exceptions are provided for certain motor controller applications The short circuit current rating isthe current the contactor is rated to open under short circuit conditions A controller must be selected that has a short circuit rating that equals or exceads the short circuit current available at its line or supply terminals M otor controllers are provided to start and stop the motor Branch circuit short circuit and ground fault protection is provided on the line side of the motor controller by a circuit breaker or fuse The newly required short circuit marking can be thought of as a withstand rating T he concept is that the motor controller will remain intact while carrying short circuit current until the circuit breaker or fuse on the line side opens the circuit The product safety standard for industrial control equipment UL 508A 2001 Supplement SB provides an example of an approved method for determining the short circuit current rating Other markings required on the contr
58. nd output circuits that use opto couplers to provide additional isola tion When wiring a PLC it is extremely important to avoid making external connections that connect logic side circuits to any other Frey Sk Tromm ar Fick Sek Irerio dr mo hay Maw r S H Liceo inp r tan LEL rj ohr Vo IF L ni i Pore e ur cu Cru Pal dam 7 i r rear Loro ar bid Figure q Mra teh ws bas Gok Coo Es soma Electrical isolation provides safety so that a fault in one area does not damage another Using Figure 5 as reference we see a transformer which provides magnetic isolation between its primary high voltage and secondary control voltage sides A powerline filter provides isolation between the control power source and the electronic devices Continued p 26 gt gt 25 Technical Review WAUTOMATIONDIRECT Figure 5 also shows some general suggestions for device grounding and distributing the control power to various devices along with individually fusing these devices Proper grounding is one of the most important things in good automated control system design T he more details we can show on the schematic to reflect all points that need to be grounded the better chance we have of a properly grounded control system that provides both safety and functionality PAm A LA et uu i ars am m am nr mt il PF N TETEN ee gt ET Mula La eke m E Lk H ee ee p lla eO OMA a LL En i i
59. nibbles isa byte Sixteen bits or two bytes isa word Table 1 Thirty two bits or two words is a double word Table 1 Binary is not natural for us since we grew up using the base 10 system which uses numbers 0 9 In this article the different bases will be shown as a subscripted number For example 10 decimal would be 10 p Table 2 shows how Base 2 numbers relate to their decimal equivalents A nibble of 10012 would be equal to a decimal number 9 1 23 1 20 or 817 119 A byte of 11010101 would be equal to 213 1 27 1 26 1 24 1422 1 20 or 128 7 6419 1619 410 110 Table 2 H exadecimal N umbers Asyou have probably noticed the Binary numbering system is not very easy to interpret For a few bits it is easy but larger numbers tend to take up a lot of room when writing them down and it is difficult to keep track of the bit position while doing the 22 conversion T hat is where using an alternate numbering system can bean advantage O ne of the first numbering systems used was H exadecimal or H ex for short H ex is a numbering system that uses Base 16 The numbers 0 919 are repre sented normally but the numbers 109 through 154 are represented by the letters A through F respec tively Table 3 This works well with the Binary system as each nibble 1111 is equal to 1515 Therefore for a 16 bit word you could have a possible Hex value of FFFF1 See Table 4 for an example
60. oller include the manufacture s name or identification the voltage the current or horsepower and other necessary data to properly indicate the applications for which the controller is Suitable Four exceptions were added to exempt the short circuit current rating marking Exception No 1 exempts certain controllers for small motors as allowed in Part VII such as clock motors attachment plugs and recepta cles and snap switches The second exception permits controller short circuit current ratings to be marked else where on the assembly The third exception covers applications where the short circuit current rating ismarked on the assembly in which the controller is installed Exceotion No 4 exempts controllers rated less than 2 hp at 300V that are listed exclusively for general purpose branch circuits Section 430 32 A www automationnotebook com covers continuous duty motors more than one horsepower The wording in this section indicated motors used in a continuous duty application required overload protection continuous duty motors used in non continuous applications did not A change was made since the previous wording could have led indi viduals to think motors are rated as continuous duty T he duty of a motor is determined by the motor s application and defined in Article 100 under duty A motor rated by the manufacturer as continuous and used as other than continuous duty requires no overloads Sect
61. ontrol Power Visit www automationdirect com circuit_protection for more Contactor Features AUTOMATIONDIRECT Telemecanique Allen Bradley information on our complete line of circuit protection products Manual motor starter Fuji Electric Transformers Mapua motor startegs NDS eee oe e ae 0 pa O Starting at 39 Non fused e Can be ueg wito Lg d Qop contactors e 100 to 500 continuous VA models r 08E listed group mot 40 Amp 46 218 210 Designed for high inrush applications Disconnects saree Contactor SC E2 110 VAC LC1D40 100 C37D00 requiring reliable output voltage stability Starting at 19 e Circuit breaker functions plus overload ie etree a en 10 Amp Manual 46 fey 115 196 Used for breaking and disconnecting el Ja romp Motor Starter BM3RHB 010 GV2P14 140M C2E C10 equipment loads of up to 600 VAC Two frame sizes up to 63 amps This product includes 1 N O Aux contact U p to 50 KA break ng Capacity at 480 VAC All prices are U S list prices AUTOMATIONDIRECT prices are March 2005 prices Allen Bradley prices taken from bors aa 153 PLOO1B EN P Sah tember 2004 Telemecanique prices taken from website http www squared com as O or Seplem R t t t comparisons are made to closest competitor product specifications available at the time Prices and specifica tions may vary by deak 0 ary ac ua or er and eenfauration All product names trademarks and registered trademarks are the property of their respectivemanufacturers A
62. pated to get the The Evolutionary PLC Past 2 2002 Voted 1 service by independent survey Y Chip McDaniel facility ready but thanks to great Presentand Future Steven Noto planning and teamwork we re settled Control Design magazine s Readers Choice Awards 2002 Tom Elavsky in and managed the move without any Business Notes 13 best service of any supplier for PLC Hardware and PLC Software major issues was hoping we d have pales ngs On in the Automation ndustry stories to tell about an incident or two TO ut the whole process went off without User Solutions 14 O 2003 Voted service by independent Survey a hitch One of the more exciting Downtime Monitoring With PLC Control Design magazine s Readers Choice Awards 2003 CONTACTS elements was the purchase of a golf Technology best service of any suppler for PLC Hardware Operator Interface Automationdirect com In cart that we use as a taxi between Rte and Terminal Blocks received the highest scores of any supplier salle aces C the buildi Feature Story 15 3505 Hutchinson Road MOS 2005 DARPA Grand Challenge EA z4 C ing GA 30040 W hile waiting on our office reno tonal iesign a 2004 Voted 1 service by independent Survey a vations we concentrated on puttingout Technology Brief 21 Control magazine s Readers Choice Awards e Control Design s Readers Choice Awards our 2005 catalog Vol 10 It s amazing EN418 Directive 2004 best ser
63. r customers a comprehensive system for tracking uptime down time production efficiency and more Our initial goal was to develop a system to report machine downtime for customers in the fastener making industry who were concerned with the productivity of their headers and thread rollers Some of these machines were monitored by our existing IM PAX process monitors some were monitored by competitors monitors and some were not monitored at all We needed a system that could track production and uptime downtime for each machine We built a basic system using an EZTouch 6 inch touch screen and a DLO5 PLC We programmed the PLC to count pulses from a magnetic proximity sensor positioned to detect parts as they leave the machine T he program tracks produc tion counts and determines downtime by calculating occur rences of 5 minute periods during which there was no signal PLC timers and registers store the times and counts and the touch screen provides access to this data When a downtime incident occurs a special screen prompts the operator to select a downtime reason from a list T his information is logged in the PLC and used for analyzing downtime causes To ensure that a reason is entered a PLC controlled relay is used as an interlock to prevent the machine from restarting until the operator responds A DO 01MC option card gives the PLC access to a clock so it can track data by day and shift Using one of the new IM PAX TimeSaver S
64. rates any of four standard motors e Optically isolated inputs ready for 5 VDC logic from DirectLOGIC PLCs e No software or add on resistors required for drive configuration 9 position dipswitch setup E NEMA 23 Stepper Motor STP MTR 23055 Four standard motors with connectorized pigtail The SureStep stepping family has four standard motors to handle a wide range of automation applications such as wood working assembly and test machines Our square frame or high torque style stepping motors use 2 phase technology with 200 full steps per revolution 1 8 per full step We have NEMA 17 23 and 34 mounting flanges with holding torque ranges from 83 oz in to 434 oz in A 20 foot extension cable which can easily be cut to length is available to make installation a snap Use Direct LOGIC PLCs and SureStep for positioning In asimple rotary indexing application a fixed trapezoid profile is programmed for the high speed counter module in the PLC The counter module is O S ta wired to the microstepping drive for pulse and direction This system provides smooth movement of the rotary table to allow product to be filled into individual containers equal distances apart NEMA 17 Stepper Motor STP MTR 17048 NEMA 23 Stepper Motor STP MTR 23055 Other stepper applications e Pick and place e High speed cut to length Stepper Motor Extension Cable STP EXT 020 Check out our prices 6430 001 K
65. s there are differences in the way that a PLC interprets it While all of the formats rely on the Base 2 numbering system and bit coded data the format of the data is dissimilar Table 8 shows the bit patterns and values for the various formats www automationnotebook com a 4 4 IE n ae e wl tome i ae Pt tT O OS O O O O O O O O E Table 8 D ata Type M ismatch D ata type mismatching is a common problem when using an operator interface Diagnosing it can be a challenge until you identify the symptoms Since a PLC uses BCD as the native format many people tend to think it is interchangeable with Binary unsigned integer format T his is true to some extent but not in this case Table 9 shows how BCD and Binary numbers differ i L A Eil E il iil MT TT di A IAN mn MO A AI 1 I Table 9 As the table shows BCD and Binary share the same bit pattern until you get to the decimal number 10 O nce you get past 10 the bit pattern changes The BCD bit pattern for the decimal 10 is actually equal to a value of 16 in Binary causing the number to jump by six digits when viewing as BCD With larger numbers the error multiplies Binary values from 10 to 15 D ecimal are actu ally invalid for the BCD data type Let s look at a larger number shown in Table 10 a COS E 1000000 1004 011100 00 0000 0000 0000 Table 10 Continued p 24 gt gt 23 Tech Thread Numbering Sytems Continued
66. s an extra margin of safety and ahigher level of integrity in the proper func tioning of the Emergency Stop switch Without the self monitoring circuit contact block there would be no detection of a fault if the contact block became separated from the Emergency Stop operator The self monitoring circuit contact block is designed so that as the contact block is mounted onto the operator the plunger depresses and closes the self monitoring circuit If it becomes disengaged the circuit will open and indicate a fault condition 21 Tech Thread Numbering Systems Explained WAUTOMATIONDIRECT Numbering Systems by Keri Schieber AutomationDirect here are several types of numbering systems typically used in automation equipment Binary H exadecimal Octal BCD and Floating Point Real H ow to usethem can be confusing This article from our Technical Support web page explains the different numbering systems Binary Numbers Computers including PLCs use the Base 2 numbering system called Binary or Boolean T here are only two valid digits in Base 2 0 and 1 OFF and ON You would think it would be hard to have a numbering system built on Base 2 with only two possible values but it can be done by encoding using several digits Each digit in the Base 2 system when referenced by a computer is called a bit W hen four bits are grouped together they form what is known as a nibble Eight bits or two
67. s and outputs Full voltage reversing 3 phase motors This diagram is for 3 phase reversing motor control with 24 VDC control voltage It uses two contactors two auxiliary contact blocks an overload relay a mechanical inter lock two normally open start pushbuttons a normally closed stop pushbutton and a power supply with a fuse The forward reverse and stop circuits can also be controlled using PLC inputs and outputs Full voltage single phase motors Wye delta open transition 3 phase motors T he following diagram is shown for 3 phase motor control of a delta star connec tion It uses three contactors an overload relay one auxiliary contact block anormally open start pushbutton a normally closed stop pushbutton an on delay timer of 0 20 seconds and a power supply with a fuse The start stop and timing circuits can also be controlled using PLC inputs oo and outputs This diagram is for single phase motor control It uses a contactor an overload relay one auxiliary contact block a normally open start pushbutton a normally closed stop pushbutton and a power supply with a fuse The start and stop circuits can also be controlled using PLE inputs and outputs p i A ee if r a 1G ur ae 0 E i J j R i a i k yilon Jiu E THISINFORMATION PROVIDED BY AUTOMA TIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED
68. t 24 VDC Output Metal Case 1606 XL60D 0 60W 2 5A Output 24 VDC Buffer Module Metal Case 1606 XLBUFFER WA Prices may vary by dealer Many other part numbers are available from all vendors All prices are U S list prices AutomationDirect prices are June 2005 prices A B prices from http www ab com 4 7 2005 WAUTOMATIONDIRECT weanwaulomationdirect com 1 814 633 0405 21 value in autbomadion A A AAA A A E A i Product Snapshots Press Releases WAUTOMATIONDIRECT Aut omation Notebook DataNet OPC software is here Cumming GA M ay 4 2005 AutomationDirect now offers DataNet OPC by BizWareD irect This new software product keeps people connected to plant operations without binding them to the confines of their facility DataNet OPC uses Open Connectivity OPC technology to communicate live data from industrial devices to a Web page with no HTML programming required Data is then available for viewing printing or archiving on any computer anywhere the Internet or company intranet is accessible For plants that use multiple PLC brands D ataN et OPC is ableto provide a more unified approach to data display and logging DataN et OPC offers many other useful features designed to make indus trial data more accessible and useful Dynamic colors allow users to deter mine the status of their plant operations at a glance and can be used as an earl
69. t ISA show in Mexico In June AutomationD irect participated in its third ISA Expo Control show in M exico City M exico T he company has been actively marketing products in Mexico for 3 years working with a local distributor Lasso located in M onterrey T his year s show was the best so far many attendees indicated their awareness of AutomationD irect because of the annual trade shows and other marketing campaigns T his year s booth featured a slide presentation of product highlights as well as a tutorial on how to use the Web site for selecting and purchasing products T here were also interactive demos and product displays including PLCs drives and HMI Nanotechnology for industry One of the many technologies that seems to be making the transition from theoretical science to possible practical application is nanotechnology A combination of engineering and chemistry this area of research focuses on the manipula tion of objects measured in nanometers a billionth of a meter or to help envision the size in practical terms approximately one fifty thousandth the diameter of a human hair M ethods developed in the laboratory allow the construction of devices or materials atom by atom Atomic or molecular manipula tion is already benefiting many industries such as medicine manufactured goods and materials manufacturing T he minia turization of electronics by scaling down has made those goods smaller and less expensive in rec
70. t can cause considerable damage Inductive load devices devices with a coil generate transient voltages when de energized with a relay contact W hen a relay contact is closed it bounces which energizes and de energizes the coil until the bouncing stops T he transient voltages generated are much larger in amplitude than the supply voltage especially with a DC supply If using a PLC the final section of our schematic will show the input and output modules Figure 7 is an example of the wiring for an input module We would make use of reference line numbering and in most cases we would show all of the input modules first then the output modules If we have analog 1 0 we would want to show the analog inputs then the analog outputs and finally our discrete inputs and outputs G enerally we would use one sheet of our schematic to show each module 0000000400 Automation Notebook Fall 2005 Issue Five Pa e E PF mm Ed aj ml ro i Wal LEHT Ha E a ma m J Figure 7 Panel Layout O nce we have our schematic finalized the next step is a panel layout drawing In most cases the actual panel is referred to as a subpanel We can mount all the components to a structure the subpanel wire all the components and do this before mounting the subpanel in the control system enclosure T he panel layout drawing should be done to scale and include dimensions for the panel builder
71. to grow due to the increased flexibility of today s PLCs and technology advancements that yield overall better performance The Greatest C hange Possibly the most significant change in the PLC market in recent years lies in the communications arena T hink about it What single development has literally revolutionized the way PLCs are programmed the way they talk to each other and how they interface with PCs for HMI SCADA or DCS applications N ot a tough question in a word the answer is Ethernet 12 Use of Ethernet communications on the plant floor has basically doubled in the past five years W hile serial communi cations remain popular and reliable Ethernet is fast becoming the communications media of choice with advantages that simply can t be ignored Speed of the network Ease of use i e setup and wiring Availability of off the shelf networking components Convenient built in communications setup It s not every day you can say you picked up acomponent for your industrial application at Wal M art or from a Web site that makes buying a snap Ethernet communications modules are readily available with high speed performance 10 100M b and flexible protocols For example AutomationD irect now offers Ethernet option modules for the DL05 06 DL205 and DL405 PLCs These modules install easily in an option slot and allow peer networking among PLCs and PCs for as little as 175 per node 10M b HO ECOM module for D
72. to follow when laying out the components Special attention should be given to component location and spacing We need to follow the manufacturer recommended mounting distances and clearances Figure 8 is a partial example of a panel layout drawing TO AT A CH ry lou 11 El Figure 8 The higher voltage devices those that operate at 240 480 VAC should be mounted toward the top of the panel keeping as much distance as possible between the high voltage devices and any electronic devices such as PLCs DC power supplies elec tronic timers etc Keeping the high voltage devices toward the top allows us to cover all of the high voltage devices with a non conductive safety shield for personnel safety It keeps the lower voltage devices grouped together allowing access to wiring termi nals that will aid in troubleshooting our control system In some cases a metal partition between the high voltage section of our control panel and any sensitive electronic devices can act as a shield from any EM generated by the high voltage devices In our panel layout design we need to include wire duct between the various components The wire duct simplifies the wirerouting between components keepsthe wiresin place makes working with the wires easier and givesthe panel a well organized look We should also make use of terminal blocks in our design www automationnotebook com Terminal blocks can be sized organized and even
73. trical Code NEC publication NFPA 70 Further information can be found at http www nfpa org Another good reference from the N FPA is Electrical Standard Industrial M achinery publication NFPA 79 3 Additional UL information can be found at http www ul com controlequipment devices html 4 Information for the N ational Electrical M anufacturer s Association N EM A can be found at http www nema org N EM A is also being harmonized with the International Electrotechnical Commission IEC www iec ch and other European standards Additional information can be found at the Global Engineering Documents Web site www global ihs com Global Engineering D ocuments is also the source for obtaining NEMA IEC and CE documents 5 Additional information can be found on OH SA s Web site http www osha gov SLT C controlhazardo js 28 WAUTOMATIONDIRECT FYI Wiring Gombinat ions How to Wire a Motor Starter by Keri Schieber AutomationDirect he Technical Support page on the AutomationD irect web site is full of valuable information and is available 24 7 T he following was referenced from the Technical and Application N otes section A motor starter is a combination of devices used to start run and stop an induc tion motor based on commands from an operator or a controller In North America an induction motor will typically operate at 230V or 460V 3 phase 60 Hz and has a control voltage of 115 VA
74. vice of any supplier for PLC 2004 best service of any supplier for PLC Phone 1 800 633 0405 f Hardware PLC Software Operator Interface hardware I O Systems and Terminal Blocks how much team effort goes into Tech Th read 22 and Power Supplies or 1 770 889 2858 producing it This one is over 1 750 Numbering Systems Explained i P is aac a T gi Fax 1 770 889 7876 pages filled with more than 5 500 parts urvey top service rankingsin I O RR igs A EEE EES l x Products Operator Interface Hardware and including many new ones If you Technical Review 24 Software and PLC Hardware Software Our award winning tech service is FREE haven t received it yet please fill out the A et pel a N u y request form on page 7 of this publica Specification Design and tion and we ll send one out right away Installation oe This issue of Automation Part3 Design www automationdirect com notebook focuses on the release of the Monday Friday 9 a m to 6 00 p m EST AutomationDirect is committed to bringing you the best E 2005 NEC We invited Phil Simmons ths ia teeta 28 E 5 a i a automation products at prices that won t break your budget te Copyright 2005 Automationdirecticom of Simmons Electrical Services to With a selection of over 5 500 quality industrial control products backed by consistent i iare q i deslinda dla 3 Incorporated All Rights Reserved discuss some of the changes hope you The Break Room 30 Pd
75. visit us at www automationdirect com pushbuttons lights WAUTOMATIONDIRECT www automationdirect com 1 800 633 0405 E A the 1 vafue in autoriti ee AL Bs dr L j am js A A y rr Automation Notebook Fall 2005 Issue Five Technology Brief EN418 Directive With compliance to code and safety regulations continually taking on a more influential role across the industry we will focus on European M achine Safety Directive EN 418 Eaton Cutler H amme supplied source information that has been compiled for the benefit of our readers EN 418 What is it N 418 isthe European Standard for the Safety of M achinery Emergency Stop Equipment It defines specific requirements for energency stop devices and actuators These requirements are summa rized as follows e All Emergency OFF devices must be self latching maintained devices W ith regard to an E Stop this means it must be either a push pull or twist to release device e The latching mechanism must be engaged prior to the electrical contact change of state to avoid a momentary OFF signal e All devices must have a Mushroom head that is red in color e The background immediately surrounding the Emergency OFF device must be yellow in color e All Emergency OFF devices must have positive opening direct opening operation This means there must be a direct mechan ical link between the operation of the mush room head and the contacts
76. y warning system to alert personnel of abnormalities in operations In addition a math tool allows the user to request 6 that calculations be performed on the raw data before it is displayed Visitors to this year s National M anufacturing Week were exposed to this feature first hand when DataNet OPC was used along with DataWorx to compile and display test scores in the Automation Q Challenge OPC technology allows easy and inexpensive data collection and display because it is supported by so many different devices DataNet OPC is compatible with any industrial device that runs on an OPC 1 0 or OPC 2 0 compliant server Edison fuse line has multiple applications Cumming GA M ay 12 2005 AutomationD irect now carries prod ucts from the Edison line of fuse prod ucts Edison Fuse is a subsidiary of Cooper Industries the worldwide leader in circuit protection All Edison fuses can be cross referenced and used as replacements for other name brand fuses AutomationD irect offers the most popular 13 32 x 1 1 2 models of the Current Limiting Class CC and the Class M M idge general purpose fuses for industrial control applications Because of their current limiting performance the Class CC products are sometimes regarded as an upgrade to the Class M general purpose fuses The CC line is recognized for NEC branch circuit protection and Type 2 coordi nated applications for IEC or NEMA starters contactors
77. y available in seven colors 30 mm HT8AAGA w contact block Pilot lights and push to test models ne T in seven colors o Selector switches in knob or lever versions NEMA 1 2 3 3R 4 4X 12 and 13 rated E T N Cutler Hammer 22mm E22LTA2QB w contact block Compliant with EN 418 European Machinery Directive Flush extended illuminated or non illuminated and mushroom pushbuttons many available in three colors Pilot lights and push to test models Two or three position selector and keyed switches Space saving non metal devices useful in hazardous environments check out our prices Pushbuttons 22 mm pushbutton flush black operator 1 N O contact Allen Bradley A Ss mer oes 3140 2 2v 35 40 8 800T A1D1 AutomationDirect prices are from Volume 10 June 2005 catalog Allen Bradley prices are from Publication A115 PLOO1B EN P September 2004 and www ab com 06 03 05 All prices are U S list prices All product names trademarks and registered trademarks not owned by AutomationDirect are the property of the respective manufacturer AutomationDirect disclaims any proprietary interestin the marks and names of others Price Part number 6 00 GCX1100 10 25 E22HV2X4 16 00 HT8AAGA 24V indicator light red 30 mm pushbutton flush green operator 1 N O contact Enclosures 22 mm metal pilot devices and stacklights For more information on pushbuttons
78. y inspectors these prod ucts are tested by DEM KO a third party European Standards company W hat else should know Ensuring compliance with EN 418 is imperative to avoid problems associated with even minimal non compliance M ost major Suppliers of pilot devices have products that may meet the requirements of EN 418 but some do not carry a third party testing certificate O thers may have products such as momentary devices and maintained twist to release devices that do NOT meet the EN 418 requirements for positive opening Operation To ensure EN 418 compliance OEMs should thoroughly research and specify with their customer the type of E Stop device being used www automationnotebook com E22 Self Monitoring Circuit Contact Block Emergency Stop Integrity The E22 self monitoring circuit contact block by Eaton Cutler Hammer has an additional circuit to monitor its proper attachment to the Emergency Stop oper ator While this configuration is not a require ment of the EN418 specification it is an enhancement to overall E Stop integrity espe cially where safety relays are being used Withoutthe self monitoring circuitcontactblock the E Stop becomes a weak link in the E Stop safety relay circuit How it works An extra circuit is wired in series with the normally closed N C contact It monitors whether the contact block is removed from or remains attached to the Emergency Stop operator This provide
79. ystem TSS monitors on each machine produced a basic downtime recording system that worked very well For data access we developed a data collection program using LookoutD irect a PC based HMI and acquisition package to collect the numbers from the PLCs across a serial network and display them in real time As the system grew and features were added we did have growing pains We were using almost all the memory in the DLO5 and touch screen Fortunately AutomationD irect offered numerous upgrade options We upgraded the RAM in the EZTouch panel and switched to aD L06 PLC with twice the memory T he D L06 also includes a built in clock and four option card slots so we could now use the new H0 ECOM PLC Ethernet card to achieve much faster networking T hese improvements allowed us to add additional features such as tracking data by part number tracking each operator log in 14 tracking machine efficiencies and allowing the user to enter up to 64 custom downtime reasons After upgrading the machine monitors we decided to switch from LookoutD irect to Microsoft Excel on the PCs when used with D SD ataServer Excel can access the PLC data Excel was chosen to provide more flexibility for future customization We now have a complete system built in Excel with screens for viewing live data from the shop floor and for reporting historical data this data is automatically gathered by Excel periodically and saved to files Another

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