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Issue 2, 2004 - AutomationDirect

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1. Aut omation Not ebook Autumn 2004 Issue Two Automation NOTEBOOK Contnbutors Publisher Tina Crowe Managing Editor Keri Schieber Senior Editor Jennifer Gerborg Design Manager Justin Stegall Contributing Writers Frances Richards Paul Ruland Wayne Labs Richard Palmer Tom Matyas Gary Multer Lynn Mitchell Andy Feimser CONTACTS Automationdirect com Inc 3505 Hutchinson Road Cumming GA 30040 Phone 1 800 633 0405 or 1 770 889 2858 PAX ama 1 770 889 7876 Monday Friday 9 a m to 6 00 p m EST www automationdirect com Copyright 2004 Automationdirect com Incorporated All Rights Reserved No part of this publication shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated Automationdirect retains the exclusive rights to all information included in this document Editors Note We were so pleased with the responses we received from our readers that we just had to do it again You have been telling us how much you enjoyed the technical articles in the magazine so weve tried to bring you information that s helpful and relevant As we started pulling together material for this publication we noticed a trend many of the articles were focused on power I m sure we all remember the power grid outage last year in the Northeast We asked guest writer Frances Richards to report on the industry s progress since the
2. BERBER ERERERERRRERRRRE RRR RE ERROR EE EA KUTUMA 2 004 I y z Cover Story sa a eee m m PF z A igle zl ae 2 New Produci Focus SureStep stepping system Technology Brief Control System Security Measures Feature Story Strides in Motor Technology New Column PLC Speaking Protect and connect your control systems for less jas w In today s market it pays to use quality products when building industrial enclosure systems AUTOMATIONDIRECT offers a full line of quality enclosures terminal blocks wire duct and more Enclosures zz Over 1 200 part numbers NEMA 1 3R 4 4X 12 and 4 12 Metal and Non Metal a e Hinged screw cover lift off cover pushbutton console wall mount m floor mount free standing and wiring trough Fans filters vortex coolers light kits locks latches and more q gaskets and exterior z m j moli FFIETLAL A IOTNEE PU a tt a k idi erminal Blocks e Feed through multi level ground fuse disconnect mini and more e Self extinguishing Polyamide 6 6 plastic e Self locking clamps e High contact pressure e Low voltage drop Wire Duct e Quality manufacturing e Robotically foamed in place door e Plasma welded corners e Polyester powder coated interior WIEGMANN e Stainless steel hinge pins DIN Rail Steel DIN rail for
3. the group The bottom line The North American power grid cannot be offshored as many jobs and factories have been If engineers and systems inte grators do their homework get familiar with regional planning emerging tech nologies and renewable electricity resources they may find themselves dancing the Electric Slide all the way to the bank Names to Know DOE U S Department of Energy www doe gov TheDOE s Energy Strategic Goal isto protect our national and economic secu rity by promoting a diverse supply and delivery of reliable affordable and envi ronmentally sound energy OETD Office of Electric Transmission and D istribution www electricity doe gov OETD is a new DOE program office formed to help ensure a robust and reli able U S transmission grid for the 21st century Its mission is to lead a national effort to help modernize and expand America s electric delivery system FERC Federal Energy Regulatory C ommission www ferc gov FERC regulates and oversees energy industries in the economic and environ mental interest of the American public NERC North American Electric Reliability Council www nerc com NERC s mission is to ensure that the bulk electric system in North America is reliable adequate and secure Its members include 10 regional reliability councils EEI Edison Electric Institute www eei org EEI is the premier trade association for U S shareholder owned ele
4. DeviceNet Profibus option cards High speed counter pulse output module u Learn more about our PLCs at www automationdirect com ples Order direct by phone fax or online Price with AC Power 4189 DC inputs DC outputs DC inputs relay outputs bl te wa kas v seas AC inputs relay outputs 245 ee 670 VP No All prices are U S list prices AutomationDirect prices are from Volume 9 May 2004 Allen Bradley prices are from Publication ACIG PL001D EN P August 2003 Allen Bradley Micrologix 1000 Installation Instructions Manual 176151 MicroLogix 1200 Programmable Controllers Bulletin 1762 Controllers and Expansion 1 0 User Manual Publication 1762 UM001B EN P November 2000 MicroLogix 1500 Programmable Controllers Bulletin 1764 Publication 1764 UM001A US P April 2000 Siemens prices from Siemens Energy amp Automation Simatic S7 200 Second Generation Products Pricing Edition 2G 07 03 Mitsubishi prices from Mitsubishi Electric F Series PLC Price List August 2002 Mitsubishi Electric Programmable Logic Controllers MELSEC FX1S FX1N FX2N Technical Catalog 2001 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 Call or go online to request your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com WAUTOMATIONDIRECT Craige a Asi ras v lez umri A
5. calibration of the amplifier s voltage is now rolled into the software calibration of the entire system Additionally if someone comes along later and adjusts the zero or span the calibration procedure described below can be run and the PLC program will compensate for the changes Calibration Procedure Calibration routines are often set up to simply add in a correction factor but this one point method leaves room for error over a range of readings A car speedometer that is permanently stuck at 60 mph will appear accurate If checked when the vehicle is moving at 60 mph A better calibration method uses two points a low point and a high point and then calculates a line that goes through both points We will use a 2 point calibration which requires two calibration units of specific lengths We will call these units calibration masters In our example they can be any length within the readable linear range Let s assume that one is 4 2 inches long and the other is 6 8 inches long Four values will be captured during the calibration procedure a Theactual length of the low calibration master 4 2 inches b Theanalog reading counts when the low master is measured Aut omation Not ebook Autumn 2004 Issue Two c Thelength of the high cali bration master 6 8 inches d The analog reading counts when the high master is measured From this point forward the four values a through d will be use
6. conditions 50 and 75 VA control transformers added to offering Cumming GA August 15 2004 Two new models have been added to the existing CPT line of control trans formers The50 and 75 VA models offer primary and secondary fuse boxes and 230 460 to 115 V The control trans formers are UL CSA and CE listed and are priced at 36 50 VA model and 41 75 VA model find that a great part of information have was acquired by looking up some thing and finding something elseon the way Franklin P Adams 1881 1960 Aut omation Notebook Autumn 2004 Issue Two New Product Request AutomationD irect is actively adding new products so it can become your one stop shop for industrial automation components We welcome your input we recently introduced wire duct and non metal enclosures largely in response to customer requests If you have suggestions please feel free to jot down the info requested below and fax to 770 844 4212 If you need to review our current product offering the best way to do it is to visit www automationdi rect com and click on the Site M ap link at the bottom of the home page Product Request Name Company Endusr OEM Othe Type of Business Integrator Product Suggestions WAUTOMATIONDIRECT Modernizing Americas Electric System After the Blackout the limit of its ability to meet thenation s 15 operate reliably and prepare by Frances Richards Freelan
7. that we will use later See Ladder Example 3 Ladder Example 3 Add the index created in Ladder Example 2 to the lookup table start address V4000 to find the actual address of the engineer ing unit values high and low _On SP1 ADDB Lookup Table Low Offset Binary V3100 OUT Engineering units Low Pointer Pointer V3102 04000 ADDB Lookup Table High Offset Binary V3101 OUT Eng Units High Pointer Pointer V3103 N ow that we have the addresses of the engineering units that we need we will load those values into memory loca tions for calibration In Ladder Example 4 the LD P3102 will peek into V Memory location V3102 and see what address is stored there as a hexadecimal number It will internally convert that to an octal number and useit as the address to get the accumulator data For example if V3102 is equal to www automationnotebook com hexadecimal 802 it will convert this to octal 4002 then it will look into V 4002 to find the number V 4002 2 that will be placed into the accumulator Ladder Example 4 Convert the low and high scale values to a real number format 4 Eng Units Low Pointer Pointer P3102 OUT Actual length of low calibration master V3000 Eng Units High Pointer Pointer P3103 OUT Actual lenth of high calibration master V3004 Now we need to know the low and high raw unit values for the range we are calibrating Ladder Exam
8. 8 10 and 15 models EZTouch panels start at 425 Designed and built by i AVG Cinder chnm t bry phone fam car andiirie RY i MM ER fo Frp cigi ATH Mar abc Comming FA GA AI ripirie razorani manufactures EZTouch panels and EZText panel The cammon sense way ra huy industrial cones AUTOMATIONDIRECT S EZTouch operator panels and configuration software were designed with ease of use as the number one priority When you combine that with great prices panels starting at 425 the advantage you gain is an interface solution that s both practical and profitable for OEMs and end users alike EZTouch Editor Features 32 bit Windows type application e Compatible with WIN95 98 2000 NT4 0 XP XP Pro Objects with EZ fill in the blank configuration Symbols Factory with over 2000 objects 128 colors for objects and screens e Scale objects using click n drag with a mouse e Preview objects while configuring e Copy and paste screens to other projects e Configure up to nine languages e Password protection at screen and object level Online programming Fast and EZ download to panel Configuration software only 140 Get your FREE EZTouch demo software today by going to http support automationdirect com demos html Call or go online to request your FREE 1 600 page catalog t panels sold exclusively through AutomationDirect and AutomationDirect resellers Check out www avg net
9. Ca ne p MM 1 0 GS3 21P0 289 GS3 41P0 389 DURAputsE Drive amp Badia dives pri ah aie gt n e lt NE HP Volt Glass Marathon Motor shop rockwellautomation com ia 1 229 Y547 1 311 2 0 GS3 22P0 339 GS3 42P0 419 z EE prices are Ce Y549 1 626 E205 1 454 30 653 23P0 399 GS3 43PO 449 PISZE BLE ns Gw MED S540 Yss2 1 941 t25 1 754 Blue Max www baldor com io o oo 5 0 GS3 25P0 459 GS3 45P0 499 10 hp 230 VAC 1 273 8 A 8 Ct hele Y553 2 474 E207 2 129 2000 i GS3 27P5 649 GS3 47P5 700 m ron oe z ne aes aati and teg GS3 4030 Y393 2 781 E208 2 429 E vector duty 10 GS3 2010 799 GS3 4010 849 NPAC VAR scons 349 4 2000 A o ya IDi gt PA UE ie ub ct GS3 4040 E209 3 089 Yor 3 539 z Da s to change without notice GS3 4050 E210 3 771 Y572 4 349 15 683 2015 999 683 4015 1 099 s korecon nars gt MC EES z eae 37 439 A133 63207 ID15H4100 E0 amp 1 4 au isan names e 60 GS3 4060 Rn E211 4 799 Yo73 5 294 eo UH GS3 4075 E212 5 744 574 5 984 2 RE 1 499 9 100 688 410 E213 6 764 575 7 439 Call or go online to request 30 GS3 2030 1 699 GS3 4030 1 5199 Also available in TEBC Also available in 6 pole 1200 RPM models up to 10 hp and with encoder feedback options Visit our website for availability and prices Nej FE FA EE E 1 600 ee 1200 40 6S3 2040 2 499 GS3 4040 2 299 AC line reactors 0 mee kits and Q Ee ment 10 Ya Mn 4322 7 0 M
10. It s probably not a good idea to mix email with HMI but if you must have email why not try a more loosely connected client such as Pegasus or Eudora instead of Outlook or Outlook Express Be careful about assuming that embedded systems are safe In August of 2003 several Diebold ATM machines running Windows XP Embedded were shut down because of a Windows XP Embedded RPC DCOM vulnerability which was attacked by Nachi a descen dent of the Blaster worm Ways to prevent infection include keeping up with M icrosoft patches installing only the modules needed for an application closing all unneeded ports and shutting down any services not needed especially RPC Also a properly positioned and configured firewall can help If you re designing an embedded system from scratch one way to eliminate the worms that run on M icrosoft based systems is not to use a W indows operating system Instead why not look into ONX Wind River or a flavor of a real time Linux OS Conclusion In the old days computers got viruses from users exchanging infected floppy disks The time it took to spread was very slow compared to today s nternet connected computers where viruses travel around the world many times over in less than an hour Now you can get a computer virus simply by Staying connected to the Internet Your best remedy is to stay up to date with software patches and virus definition updates and to shut off all Windows servi
11. STATES so that the addition AMERICA problem adds up Now how do we use it M ouse Trap My mother wanted to look up something on the Internet Having never touched a computer let alone the Internet showed her how to use the mouse and the significance of the hyper link She said want to see what this page says so told her to put the mouse pointer over the icon and click the left mouse button She successfully navigated the cursor to the icon picked up the mouse to eye level looked at the button she wanted to click clicked it and asked D id do it right The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at or repair Douglas Adams 1952 2001 LESLVOT 678186 78959 E Sulus pJUBNEp PP al PIO SJEDA OMY DJE SUIMJAY Z XIS U SE S T SueMSUY 30 Aut omation Notebook Autumn 2004 Issue Two Automation NOTEBOOK Please tell us what you think Log on to www automationnotebook com or send an email to editor automationnotebook com to share comments express an opinion or provide ideas for future issues We invite readers to participate in application stories technical questions and Break Room humor If you have a submission for any of these sections or an article idea please email us All submissions will be reviewed an
12. a need for talented engineers T he number of power engineering grad uates continues to decline as have the number of new engineers being hired and groomed by utilities Recent events have not yet changed this In the mean time corporate cost reductions have often forced the oldest and most knowl edgeable engineers out of utilities We see a real problem looming Second regarding the skilled workers or trades they re definitely graying and departing with knowledge that cannot be replaced The current focus here is on knowledge capture using various means to record undocumented worker knowledge says Gellings All of this bodes well for tech nical experts Utilities that have slashed their engineering departments need knowledgeable consultants such as engi neers and systems integrators to fill the gap Another area of opportunity is the need to diversify the grid s energy supply FERC in support of new rules for inte grating wind energy into the grid says Encouraging the development of inter mittent generation will increase diversity in the resource base thereby improving system reliability asa whole T he Union of Concerned Scientists supports this view as well A renewable electricity standard requiring utilities to increase their use of renewable electricity from a mere 2 percent today to at least 10 percent by 2020 was one of the few positive provisions in the energy bill recently passed by the Senate says
13. accurate control of position and speed and offers a great solution for applications requiring lower power and low cost T he SureStep family includes four standard motors and a onesizefits all step motor drive With holding torques from 83 oz inch to 434 oz inch in NEMA size 17 23 or 34 frames the motors handle a wide range of automation appli cations including woodworking assembly and test machines The motors also feature 2 8 A per phase while their square frame style produces high torque and allows the motors to achieve the best torgue to volume ratio All four motors are connectorized for easy hookup A 20 foot extension cable with locking connector is a standard option to interface the SureStep motors to the 2 phase microstepping drive The cable can easily be cut to d P E i e mar For more information on the new Sur U p SureStep li ISI S e line of products visit www automationdirect com All prices are U S list prices Prices and specifications may vary by dealer and configuration Please check with vendor before purchasing Many of the vendors listed above also offer other sizes of fixed field 1 0 AutomationDirect prices are from Volume 9 May 2004 Allen Bradley Flex 1 0 Product Data Catalog Publication 1794 2 1 Allen Bradley Flex Integra I O Product Data Catalog Publication 1793 2 1 prices from Publication ACIG PL001D EN P August 2003 GE Fanuc VersaMax Modules Power Supplies and Carriers User s Manua
14. any archives And keep in mind that 70 of industrial cyber incidents originate from within the company T he unrelenting hacker It s been a quiet week in Lake Wobegon M aybe but on the Internet quiet weeks without hackers and the viruses they create are a faded memory Whether or not your plant LAN ties into the enterprise LAN it s a good idea to have virus protection on all computers unless of course you have an embedded system that isn t exposed to the network In one recent week alone there were three or four M cAfee virus definition updates to combat various versions of MyDoom and Bagle worms W hile not all viruses or worms will destroy your data they can steal sensitive information that you probably don t want them to have Assuming they do no damage to your computer and steal no data worms can still decrease your network bandwidth to almost zilch and that s what shut down the D avis Besse plant for about six hours O nce infected by email a computer with a worm spreads its nasty germs to othe computers on your network in peer to peer fashion and to other computers around the world via email Your computers become zombies and when commanded by ahacker join an army of computers directing denial of service attacks against a planned destination for example M icrosoft N ot a virus but almost as bad If aplant floor Internet connected Pentium all of a sudden behaves like a 25 MHz 386 it may have
15. blackout and where the strategy for power resources is headed in the future We also have a power related article on high efficiency AC motors and drives and another that covers commonly asked questions about control transformers And we hope you will browse the automationnotebook com Web site We will be updating the site frequently to discuss company industry and product news and well beinviting you to join in the conversation soon We hope you will enjoy this issue as much as we enjoyed putting it together for you Fos dewey Keri Schieber M anaging Editor editorQ automationnotebook com www automationnotebook com Your guide to practical products technologies and applications Table of Contents New Product Focus 4 New SureStep stepping system Product Snapshots 6 T1H EBC100 Ethernet link Non metal Enclosures Marathon Motors line extended 2 pole supplementary protectors 50 and 75 VA control transformers Cover Story 8 After the Blackout Modernizing America s Electric System PLC Speaking 12 PLC Technology and Application Tips Business Notes 14 Goings On in the Automation Industry User Solutions 15 Feature Story 18 Strides in Motor Technology Application Spotlight 20 Hydroelectric Plant Upgrade Technology Brief 22 Control System Security Measures Tech Thread 24 Indirect Addressing Technical Review 27 Common Questions about Control Transformers FYI 28 Calibratin
16. e Two communication ports Eightfill in the blank PID loops with autotune e Optional LCD display Built in real time clock calendar Nine models available DLO5 PLC starting at 99 Eightinputs six outputs The DLO5 and the DL06 are a family of micro Expandable to 301 0 PLCs designed to fit more applications than Two communication ports Four fill in the blank PID loops with Counter autotune Eight models available H ch Speed any other PLC family in their class Starting with the DLO5 at 8 inputs 6 outputs all the way up to the fully expanded 100 1 0 DL06 these PLCs are a standard that can grow with the changing needs of your machine or process control application DLO6 Head to Head Comparison Features pat vsa Sens Mig Integrated 1 0 B Inputs Outputs a SRE data men i ntegrated communication ports Discrete on off control AC DC sink source and relay I O Integrated networking port MODBUS RTU master slave Removable terminal blocks standard ASCII in out Built in high I O for simple sinale axis moti licati Integrated real time clock ow Built in high speed I O for simple single axis motion applications META ema be cee 4 fes wa Analog control Seven analogl O option cards PID with auto tune standard Removable terminal blocks for easy wiring and setup Communication and specialty modules Two serial communication ports Modbus master slave Port 2 Ethernet
17. for other roducts suc H E E mar www automationdirect com 1 VAUTOMATIONDIRECT
18. industrial manufacturing The module can be configured using an Internet browser to access the module sH TM L configuration page or with NetEdit a free W indows Software configuration utility The module supports the full lineup of Terminator I O discrete analog and motion control modules It is priced at 249 6 Non metal models added to growing enclosure line Cumming GA July 15 2004 Several non metallic enclosure models have been added to AutomationD irect s line of enclosures Premier series enclosures are available in Opaque hinged cover models with pull latches or screw covers as well as clear hinged models with screw covers or link lock latches Prices start at 32 00 Junction box enclosure models are also available Slimline series junction boxes carry aNEMA 4X rating and are priced starting at 16 00 N ew pushbutton enclosures for 22 or 30 mm size pushbuttons feature lift off covers with up to seven pushbutton cutouts The 30 mm multi hole units are also available with 4 6 9 12 16 20 or 25 cutouts Prices start at 18 00 JIC series enclosures are available in opaque lift off cover models with four screws opaque hinged covers with two screws opaque hinged covers with quick release latches hinged covers with link lock latches and windows and hinged covers with quick release latches and windows Prices start at 24 00 N ew 3R or 4X control series units are also available wi
19. on your next installation zra AC Sensorless che o RNI up to 100 hp m KC motors Up to 100 hp The new DURAPULsE series builds on the simplicity ieee a to operate within U S Pkg and flexibility of our GSL and GS2 series drives Internal dynamic braking circuit for models The digital keypad 230 VAC and adds sensorless vector control and autotuning under20hp includes a two line x 16 DuraPulse 1 Price 40 microMax as well as optional encoder feedback for tighter Automatic torque and slip compensation character LCD display tp Drive BE USS Mu RE USS AC inverter Programmable jog speed five status LED indicators 5385 1536 389 396 duty speed control DURAPuLse configuration settings Th E Y551 546 gt e Three analog inputs and one analog output P and nine function keys eee offer fast and easy out of the box operation with Eleven digital inputs The keypad is designed 683 28P0 zk Y541 659 carefully selected default values for the most Four programmable outputs three digital with defaults for the North __688 25P0 O Y372 711 Y543 771 common a
20. up or down until they reach the desired positions North Fork Electric engineers then implemented the third and final tier of control and monitoring The LookoutD irect SCADA system communicates to all the PLCs over an Ethernet network performs supervisory control and collects data that is easily passed to the plant s information system The installation was completed in four weeks to provide Lockhart Power with apowerful yet simple redundant control system that uses their familiar hardwired design as the manual control mode Contactors Starting at p 12 m 5 i sil ki k a a Contactor features Three compact frame EUJS ua sizesupto300Hp ELECTRIC AA 2S 24 VDC 24 VAC M se 120 VAC and gt 240 VAC coils Starting at e Larger models use a SUPER MAGNET for 22 high operating reliability Ae protection Thermal Overload terminals Relays Overload features Overload open phase protection High precision scale for current adjustment dial Isolated N O and N C contacts Ambienttemperature We carry a complete compensation line of motor control Manual auto reset accessories selectable Manual trip mechanism Trip indicator Finger protection terminals Application help Technical Questions Call 770 844 4200 Motor Controls Head to Head AutomationDirect VS Competition AutomationDirect Features Fuji Allen Bradley 12 75 s 94 66 69 SC E02 110 VAC L
21. A JEM KI rigiri rararvad Business Notes WAUTOMATIONDIRECT Goings On in the Automation ndustry i AutomationDirect switches Web seminar hosting service To improve service both internally and to seminar atten dees AutomationD irect is switching their Web seminar hosting service from Webex to Raindance effective September 1 For past seminar attendees who may have bookmarked the seminar landing page in their Internet browser the new address iS http automationdirect raindance com A link to the current live seminar schedule and registration as well asa list of pre recorded seminars available for download is always avail able on the home page of www automationdirect com Durapulse com Web site focuses on AC drives W ith the Internet becoming an increasingly valuable tool for engineers to do research automation suppliers are taking advantage of new technologies to present product information in more informative and interactive ways A case in point is AutomationD irect s new Web site focused on AC drives www durapulse com The site specifically highlights the recently launched DU RApulse line of sensorless vector drives A high bandwidth version of the Web site makes use of audio video and visually oriented demonstrations to provide a Sot razm eee et oe ib more interactive way to learn about the product s features applications and configuration A low bandwidth version is available for dial up c
22. An engineer designing a measure ment system will generally examine the voltage or current to be provided by the measuring transducer and the counts that should result after the analog input card converts the electrical signal to a number T he conversion factors can be set up to convert counts to real world units such as pressure or force T hese theoretical or ideal factory published numbers are suitable for specifying equipment but when the system Is set up and running the actual readings and numbers will differ from the theoretical W ires will add resistances that cannot be calculated in advance and temperature changes will cause variations that must be accounted for N o analog system will run exactly per book values and thus a 28 calibration routine must correct for the differences Calibration M ethod T he calibration method described here can be applied to any analog meas urement such as pressure amperage weight length or force Let s consider an example where the length of an object is being measured We will assume that a device has been built that converts the length of the object to numerical readings via the analog input T he type of instrumentation used may be a laser measuring device an LVDT or any device that provides an analog signal that will vary with the length of the object being measured We will assume the following 1 Theobject being measured ranges from 2 to 9 inches in length and the
23. C1D09 100 C09D10 40 Amp Contactor 45 xo 218 w 148 94 Part Number SC E2 110 VAC LC1D40 100 C37D00 10 Amp Manual bu Motor Starter 44 75 ive 1 55 in 1 39 31 Part Number BM3RHB 010 GV2P14 140M C2E C10 This product includes 1 N O Aux contact Telemecanique 9 Amp Contactor Part Number and names of others Order direct by phone tax or online hz casa a gy ppl p Ne COM Na CNC Ej apige 2009 Ari oma z ulkus Cecio GA LEA SA rights marad All prices are U S list prices AutomationDirect prices are 2003 prices Allen Bradley prices taken from online store http shop rockwellautomation com as of December 1 2003 Telemecanique prices taken from website http www sguared com as of September 8 2003 Price comparisons are made to closest competitor product specifications available at the time Prices and specifications may vary by dealer and configuration All product names trademarks and registered trademarks are the property of their respective manufacturers Prices subject to change without notice AutomationDirect disclaims any proprietary interest in the marks Manual Motor Starters MMS features A zgo u utraci O Ma walk PO OLY IMOLSTTENI oa R a Fuji Electric Quality at AutomationDirect prices Fuji motor controls up to 300 Hp AutomationDirect is now offering Fuji Electric s best motor control solutions With sizes up to 300 Hp at 480 VAC this complete series of IEC cont
24. Speaking where we will share AutomationD irect s insight into PLC technology and pass along helpful application tips from our customers PLCs have traditionally suffered from the stereotypical complex of bigger must be better However in the last five to seven years smaller PLCs in the nano and micro classes have been introduced that have significantly improved capabilities previously found only in larger PLCs The need to specify a large PLC just for additional features or performance and not the increased I O count is now no longer necessary Even the smallest 1 0 count nano PLCs are capable of Ethernet commu nication motion control on board PID with autotune remote connectivity and more T his recent increase in PLC capabilities found in much smaller packages has allowed the application of PLCs to go well beyond simple on off seguential control M odern PLCs have the ability to perform functions of process control motion control data acquisition RTU remote telemetry unit and even some integrated HMI human machine interface functions all in one programmable controller Previously each of these functions often required its own purpose built controller and software plus a separate PLC for the discrete 12 control and interlocking For example the DL06 micro brick PLC can be a great alternative for a process application that would normally combine a PLC with one or multiple single loop controllers or temperature control
25. When it became our turn we struggled to communicate with the proprietor he spoke only a bit of English and our Dutch was abysmal As we gestured at the menu and pointed at the food the man finally got fed up with the incessant barking H e leaned out across the counter and shouted a long string of angry Dutch at the dog The dog immediately ceased barking and sat down We obtained our food and started to walk back to the factory The dog never made another sound As we walked past my co worker commented to me You know that dog understands more Dutch than we do laughed all the way back to the plant suppose he was barking in Dutch as well Brainteasers 1 OTTEF W hat s the next letter in sequence T hey are all letters Submitted by a reader 2 Two old friends meet after a long separation T hey swap stories talk about jobs families etc T he first man says have three children now Second man asks Really What are their ages First I ll give you clues and you try to figure them out First the product of their ages is 36 Second T hat s not enough to solve it First T he sum of their ages is the same as the address where we used to play chess Second O kay T hat s still not enough to solve it First The oldest looks a lot like her mother Second O kay know their ages W hat are they 3 Replace each letter with a unique FIFTY integer from 0 9
26. actors overload relays traditional starters and combination starters have a long list of features are in stock and available for Same day shipping AC and DC coils available 24 VDC Fully PLC compatible with surge suppression accessories 24 VAC Specialized in HVAC and Air mover applications 120 VAC and 240 VAC Standard commercial and residential voltages Starting at UL 508E listed group motor rating friendly Two frame sizes up to 63 amps Up to 50 kA breaking capacity at 480 VAC Thermal and magnetic protection Multiple coil voltages DIN rail mountable Manual ON OFF control with lockout capability External handle kits for through the door ON OFF control optional Adjustable current setting with anti tamper cover Front and side mounted alarm and auxiliary contacts optional Trip free design Add a contactor link module and base plate to complete the combination starter Call or go online to request your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com VAUTOMATIONDIRECT Technology Bnef WAUTOMATIONDIRECTE Automation Notebook Autumn 2004 Issue Two Cont rol system Security Measures How secure is your control system by Wayne Labs Guest Writer M aroochydore Australia April 2000 ired by the contractor who installed the control system at the local water treatment plant engineer Vitek Boden was then rejected for a job by city co
27. an infection or if this computer is also used to surf the Web and allows downloadable installs extreme slowness might be due to adware spyware or other unwanted Trojans Some Web sites that add tool bars to your browsers can install as many as three or four programs or services that track your every move on the Web and relay the information to marketing firms While these are technically not viruses they can have the same effect on your machine they bog it down to a crawl Sometimes these programs will give you a warning about what they ll install but it s usually buried in a couple thousand words of boilerplate Sometimes if you re lucky they ll show up in Add Remove Programs where you can get rid of them H ow to avoid problems Avoid connecting your HMI or control computer to the network and don t connect a phone line for remote access If either is necessary and your plant LAN and enterprise LAN are tied together talk it over with IT and make sure you at least have routers firewallsin between to control traffic so only specific hosts get to talk to the plant floor system Plant networks can be put on separate subnetworks which provides some isolation Use routers to close unnecessary ports and firewalls to exclude hosts and domains Use only the Professional versions of Windows 2000 and XP If you still have Windows NT floating around don t expect Microsoft to support it much longer Although it s an
28. analog device is capable of measuring over this range 2 Theanalog device provides a voltage signal to the analog input card T he voltage is converted to anumber or counts by the analog card The count resides in real time in a register in the PLC and the ladder logic can perform Math functions using thisnumber For example let s assume that an object is being measured 2 inchesin length and the count is 100 and when an object 9 inchesin length is measured the count is 3900 The nice thing about the method described here is there is no need to be concerned with the amount of voltage provided by the transducer or received by the analog input card By utilizing the counts and then converting the counts directly to length the voltage becomes irrelevant as long as any change in counts is linear with any correspon ding change in length T his provides the advantage of not needing to be concerned with calibration or setup of the transducer and its amplifier Too often time is spent setting the zero and span of amplifiers and signal conditioners where a person might determine This object measures 2 3 inches therefore my voltage should be 1 2 volts T hen they proceed to set the zero and span to achieve an exact voltage for the corresponding length By using the calibration method described here this process is no longer necessary and the exact voltage at any given length is of no concern T ime issaved because the
29. andards that address seven main areas balance power generation and demand continu ously balance reactive power supply and demand to maintain scheduled voltages monitor flows over transmission lines and other facilities to ensure that thermal limits are not exceeded keep the system in a stable condition operate the system so that it remains in a reliable condition even if a contingency occurs plan design and maintain the system for emergencies August 14 Revisited What happened on August 14 2003 to cause the widespread power outage To find answers President George W Bush and then Prime M inister Jean Chr tien established a joint U S Canada Power System Outage Task Force An interim report was published in November 2003 with a final report issued April 5 2004 The task force investigated the outage to determine its causes and developed 46 recommendations to minimize the possibility of future outages According to the report the blackout could have been prevented T he outage affected approximately 50 million people and 70 000 megawatts M W of electric load in Ohio Michigan Pennsylvania New Jersey New York Connecticut Vermont M assachusetts and the Canadian provinces of Ontario and Qu bec It started a few minutes after 4 p m Eastern Daylight Time and lasted four days In some areas with a total cost estimated between 4 billion and 10 billion Key parties included FirstEnergy Corp FE American El
30. approving a settlement with N STAR Electric that exempts renewable energy facilities from standby charges Andy Feimster a systems integrator at North Fork Electric Crumpler NC also works in the power and utility industry H e acknowledges the difficulty of working with today s grid The complexity of the system is such that no single human being can truly understand it It s grown almost organically he says T he effects of deregulation have served to further confuse the situation Feimster notes T here are opportunities for inte grators to provide systems and services to electric utilities but it can be very complicated Utilities are brokering power all over the place and systems are being Interconnected in ways they never have been ways they were never designed for Feimster believes the evolving grid may offer some opportunities for engi neers and systems integrators H e notes that the line between industrial grade equipment and utility grade equipment is beginning to blur In many cases he says the industrial grade has become advanced and reliable enough to be spec ified into power and utility work If these products are suitable for use in chemical plants that have life and death consequences for malfunctions then surely they are reliable enough for utility applications he adds see application story on page 20 that details North Fork Electrics hydrolectric plant upgrade for Lockhart Power Industrial
31. ashed red line indicates a linear line and the blue line shows the actual gallons in the tank T he equation for this curve is g z L r 2 ACOS r h r SQRT 2 r h h 2 r h 231 Where g gallons L tank length in inches r tank radius in inches and h liquid height in inches It s pretty easy to see that this would be difficult to implement in ladder logic Figure 1 H orizontal Tank Levd 24 So how do we accomplish this without performing the entire difficult math eguation T he answer is to pre calculate several points across the scale and then do alinear calibration equation between those points O bviousy this method will induce a certain amount of error since you are taking a curve and slicing it into divi sions and then performing a linear calculation on the individual divisions The more divisions the less error but the more CPU memory consumed Creating the lookup table can be performed in several different ways One way would be to take the manufacturer s table and cut it into equal divisions Next find the values at these divisions and place the engineering units at those divisions into the table T hen dividethe raw units by the same number of divisions and use this to perform the lookup Another method is by calculation estimation For example you might take the equation and place it into a spread sheet and derive the engineering units by calculation Still another option is by manual
32. calibration although this method is sometimes nearly impossible to accomplish In the following example we will be using the manufacturer s table method with a non linear analog value such as an orifice flow meter In order to scale the non linear signal we need to divide the raw analog signal into sections If we divide the raw analog value 4095 by 10 wehave 11 sections 10 of 409 units and 1 remainder of 5 We also need to divide the manufac turer s table into engineering units by dividing into 11 sections For this example our engineering units will be 0 1 2 4 8 16 32 64 128 256 512 and 1024 See Figure 2 This is where the numbers for the lookup table come from EE EJ ASA amp T E HM M II Figure 2 Orifice Flow M eter In our ladder program the first step is to load the lookup table values into V memory variable memory Anytime you have variables that will not Ladder Example 1 Load the non linear table on the first scan _FirstScan SPO 1 Eng Units Point 1 BCD Eng Units Point 2 BCD Eng Units Point 4 BCD Eng Units Point 12 BCD V4013 Aut omation Notebook Autumn 2004 Issue Two change often if ever load them during the first scan cycle as shown in Ladder Example 1 This will save frustration if something should ever happen to the V memory such as forgetting to install a battery for backup To find the lookup table offsets which are the h
33. ce Writer here were you on August 14 2003 If you live some where other than the N ortheast or M idwest the date of N orth America s largest blackout may not be familiar to you was working on my home computer while my spouse was engrossed in vacuuming our cars W hen everything came to a flickering halt immediately blamed him for over loading our touchy circuit breakers It soon dawned on us that something drastic had occurred From our car radio we heard reports of power outages in major cities across the U S and Canada Confusion set in not to mention a bit of panic Could terrorists have coordinated this massive blackout Fortunately not this time In the weeks and months that followed causes were determined and many recommendations set forth W here are we one year later and what opportunity does this represent for our country s technical elite including engineers and systems integrators G ood news on both fronts Many plans and visions are in place and better yet opportunity abounds for those who get to know the grid Grid 101 America s electric system aka the grid nas been hailed as the supreme engineering achievement of the 20th century by The National Academy of Sciences According to the U S D epartment of Energy DOE and its new Office of Electric Transmission and Distribution OETD each day more than 10 000 power plants deliver electricity over 157 000 miles of high voltage electric
34. ces you don t need The same applies if you re running Linux UNIX For more information see the sidebar www automationnotebook com Security helps and info And by the way think twice before laying off Clarence Security H elps and Info All about spyware http www spywareinfo com Forums on security http www wilderssecurity com index php ISA Security page www isa org click on Technical Information and Communities then click on Security M icrosoft Security www microsoft com security SecurityFocus A Web site dedicated to security http www securityfocus com U S DOE 21 Steps to Improve Cyber Security of SCADA Networks http www ea doe gov pdfs 21stepsbooklet pdf U S Government Accounting O ffice C ritical Infrastructure Protection Challenges and Effort to Secure C ontrol Systems http www gao gov new items d04354 pdf W indows Task List programs http www answersthatwork com Tasklist pag es tasklist htm W hat M icrosoft is doing for security Windows XP Service Pack 2 will ship with fire wall turned on as default Future versions of Windows and microprocessors will feature a hardware enforced no execute to minimize the possibility of running a worm or virus residing in data only memory W indows components are being recompiled with the newest compiler technology to help miti gate against buffer overruns Windows Servers will be shipped with Internet Information Service
35. ctric companies EIA U S Energy Information Administration www ela doe gov EIA isthe government s energy statistical agency View its report The Changing Structure of the Electric Power Industry 2000 An Update EPRI Electric Power Research Institute www epri com EPRI is a nonprofit research consortium for the benefit of utility members their customers and society About Frances Richards Frances Richards is a freelance writer based in Chagrin Falls Ohio A former editor of several design engineering magazines Richards now writes about energy efficiency and a variety of technical topics from the comfort of her own home M ans mind once stretched by a new idea never regains its original dimensions Oliver Wendell H olmes 1809 1894 11 m i a L II p ry Cm a 1 Q A DA I Q le x li 3 fi JI 4 5 b 1 U WAUTOMATIONDIRECTE amp PLC Technology and Application Tips by Paul Ruland AutomationDirect Product Manager PLC 1 0 and PC Controls Group Over the past ten years AutomationD irect formerly PLCDirect has provided PLC Programmable Logic Controller products in many shapes sizes and I O counts and with a wide variety of features Since PLCs were the prod ucts on which this company was founded it is only natural to devote a column on the subject of PLCs in the new Automation N otebook So welcome to the first installment of PLC
36. d considered If you area non subscriber and would like to be included in the next mailing of AutomationN otebook please select Subscription Information on the Automation N otebook Web site and complete the details You can also reguest FREE stuff including our new 2004 catalog and our CD ROM featuring the entire catalog and demo software f you provide your email address we will send news and product information from time to time as well For those who prefer to speak with us in person please call 1 800 633 0405 x1845 Thanks for your participation and we look forward to hearing from you Did you see him fA fA FA FH A A ih T his issue of Automation N otebook contains a hidden smiley guy H eisafamiliar icon associated with our advertising tables and charts but if you re not sure what he looks like we have a sample above If you re one of the first to respond with his location you will be included in the drawing from our big box of free stuff T his is not the same free stuff that you can request anytime but new more exciting freebies that we have available H e could be anywhere If you locate Smiley and wish to be entered in the drawing please send an email to editor automationnotebook com with Smiley s location We will collect all responses and award multiple prizes All entries received thru O ctober 12 2004 will be eligible Disclaimer Advertisng pages containing charts and or tables featuring Smiley are not dig
37. d to set up themath required to covert counts to inches We will call the resulting value je The change in length for any corresponding change in counts is calculated as follows c a d b e The person performing the cali bration enters the lengths of the high and low calibration masters values a and c via the operator interface and these values are stored in PLC registers The corresponding analog counts for the high and low calibration masters values b and d are captured during the calibration routine and are also stored in PLC registers We will use the following data registers a low calibration master Register V 3000 V3001 b low master analog reading Register V 3002 V 3003 c high calibration master Register V 3004 V 3005 d high master analog reading Register V 3006 V 3007 The following ladder logic will calculate e and store this value in V 3010 V 3011 Data register V 3014 is used to store temporary math results while the accumulator is in use performing other math See Figure 1 Length C onversion After the calibration routine has been run and the values a through e are stored in the PLC the formula for converting counts to length is counts b xe a The following ladder logic will calculate the length from the counts and store the resulting length in V 3012 V 3013 The analog reading Calibrate PB from operator panel CO LDR Analog reading from the high calibrati
38. e 50 GS3 2050 3 099 GS3 4050 2 799 Braking units Ans U ETF waw o Order direct by phone fax or online VV EI Poe Braking resistors GS3 FB feedback Four and GEN port aa E me 60 GS3 4060 3 199 EMI filters rd eedpac sma ion w i GS3 4075 3 599 oards 4 The common sense way to buy industrial controls WAU TO MATI O NT JI R ECT PB I sa WET 3 999 RF filters Ethernet interface La n 2 KL i odd iu ki Ly fl 1 OI l imc HE tTI ne ols EE E tuppigkt ZNA Awttiaajm RECI Curaray GA LESA All orje rearen Feature Story Motors Drives Technology WAUTOMATIONDIRECT Strides in Motor Technology by Tom Matyas AutomationDirect Product Manager hen AutomationD irect was looking to provide customers with a high performance cost effec tive drive motor package to complement their growing line of AC variable speed drives they turned to M arathon Electric a well recognized well respected name in the industry M arathon manufactures a full line of general purpose inverter duty vector duty and NEMA premium effi ciency motors to meet the needs of a wide range of customers and specializes in severe duty and explosion proof motors for chemical washdown applications and hazardous applications M arathon s manufacturing and logistics operations are ISO 9001 2000 certified which contributes to the superior guality of all their products M arathon Electric received the highest overall customer satisfactio
39. ectric Power AEP and their respec tive reliability coordinators M idwest Independent System O perator M ISO and PJM Interconnection PJM Causes of the blackout are grouped into four main areas within the report Group 1 is summed up as inade quate system planning T hisrefersto the failure of FE and the East Central Area Reliability Coordination Agreement ECAR to assess and understand the shortcomings of FE s system especially its voltage instability and the vulnera bility of the Cleveland Akron area The report concludes FE did not operate its system with appropriate voltage criteria Group 2 is summed up as inadequate situational awareness FE didn t recog nize or understand the deteriorating condition of its system Group 3 involved Inadequate tree trimming Group 4 centered around inadequate RC relia bility coordinator diagnostic support e e e 1000000 Aut omation Notebook Autumn 2004 Issue Two This refers to the failure of the interconnected grid s reliability organiza tions to provide effective real time diagnostic support Specific causes of the cascading blackout fall into one of these four groups To enjoy the full report grab a cup of coffee and visit www electricity doe gov Click on Blackout at the top of the page Grid Progress Fast Forward O ne Year M any of the immediate concerns addressed in the final report have been corrected a large number o
40. endently choose the most appropriate motor drive package for their needs For complete technical specifications and pricing for the Marathon motors and DURApulse AC drives offered by AutomationD irect visit www automationdirect com drives www automationnotebook com 1 9 Application Spotlight WAUTOMATIONDIRECT Cost effective I O simplifies hydroelectric plant controls upgrade by Lynn Mitchell by Andy Feimser Operations Superintendent President Lockhart Power Company North Fork Electic electric plant located on the Broad River in upstate South Carolina and services over 6 000 direct customers and 6 000 indirect customers over its 90 mile trans mission network The plant includes an 8 gate dam feeding a canal that channels the water flow to the powerhouse which contains five turbine generators with a combined power capacity of over 17 M W The dam and turbine control system receives data from power flow and level sensing devices to perform monitoring and control of the dam generators and associated eguipment ockhart Power C ompany owns and operates a hydro The previous control system installed in 1987 was a proprietary micro processor based system that had become obsolete Lockhart required a control system that would provide open networking capabili ties and result in a lower total cost of ownership T he new system needed to coexist with an upgraded design of the existing hardwired generator con
41. f them by FirstEnergy M ark Durbin spokesman for FE says We ve looked at four main areas Including voltage criteria and reac tive resources operational preparedness and action plans emergency prepared ness and operator training In addition we ve worked closely with technical NERC is working closely with FERC Federal Energy Regulatory Commission on two broad audit areas across the country according to David M eyer senior advisor for the Office of Electric Transmission and Distribution OETD NERC and FERC are focusing on compliance audits which deal with alleged violations and readi ness audits that are forward looking Between February and June of this year these two agencies audited 20 of the largest energy related entities east of the Rockies says M eyer An estimated 50 readiness audits will be completed by the end of 2004 M eyer also notes that the DOE is working closely with its Canadian counterparts to establish an Electric Reliability Organization ERO which hopes to give well defined direction and oversight to the entire North American trans mission network According to Meyer 20 Hours before blackout 8 14 03 satellite image courtesy of NOAA DMSP teams from NERC to ensure we comply with their readiness audits Durbin also notes that FE has established procedures and processes to operate more conserva tively installed new computer systems in its Ohio and Pennsylvania control cen
42. firing speed and carrier freguencies highlighted the need for further motor developments and vector duty applications made even more refinements necessary T hrough all these changes M arathon has continued to improve the capability of its products In fact Plant Engineering magazine named Marathon s microM AX Product of the Year in 2001 W hy do motors operate more efficiently when connected to a Variable Frequency Drive VFD To some degree a motor operates more efficiently and certainly with greater dependability when teamed with aVFD T his is particularly true at lower operating frequencies where iron losses are lower Any time a particle is magnetically charged in one polarity i e north and then must reverse its polarity i e south energy is expended Think of this phenomenon as magnetic friction At lower frequencies this polarity reversal occurs less frequently thus magnetic friction is reduced T he lower losses allow the motor to run cooler Unfortunately the laws of physics operate in the same manner at higher frequencies therefore motors typically run a little warmer above 60 H z W ith regards to efficiency the real issueisnot component or even the motor drive system efficiency It is really morea matter of improving the efficiency of the process that is powered by the drive motor system An example is a fan or pump application where at lower frequencies the HVAR system s airflow or t
43. g PLC Analog Signals The Break Room 30 Does your dog bark 3 VAUTOMATIONDIRECT New Product Focus what s New length if needed T he drive operates all of the four standard motors and features standard 5 VDC optically isolated logic inputs for interfacing with DirectLO GIC PLCs The SureSteo microstepping drive incorporates a 9 position DIP switch to set up the drive parameters no software or add on resistors are required for configuration The DIP switches are used for built in self test steo angle selection current level Selection and optional idle current reduction Step pulses and direction signals from the D irectLO GIC PLCs or other indexers and motion controllers are trans lated by the microstepping motor drive into precise move ments of the stepping motor shaft The 2 phase bipolar More features for ess money PC BASED CONTROL New SureStep Stepping system features high performance and torque with simple and Fieldbus network interface modules support Ethernet motors have 200 full steps per revolution or 1 8 degrees per accurate control full step Older type stepping motor drives which operate DeviceNet by Jennifer Gerborg stepping motors in full step mode can result in stalling or lost Modbus Senior Editor motion due to the potential for problems with low speed mechanical vibration To minimize these types of problems the SureStep microstepping drive uses advanced microstep pi
44. g from the low calibration master MULR Multiplier that will be used to convert counts to inches V3010 ADDR Actual length of low calibration master V3000 OUTD Length in inches of device being measured now V3012 Figure 2 observe the math in action T his makes the systems internal workings clear to anyone using the eguipment About Gar Multer Gary Multer is with MulteX F Automation nudi in Boston and has over 20 years experience designingand building custom assembly machines and test equipment for manufacturing Operations and laboratories Gary Specializes in istallation and troubleshooting of equipment He can be reached at gmulter multex org 617 262 4143 N obody got anywhere in the world by simply being content Louis L Amour 1908 1988 29 The Break Room Humorous stories Cartoons and Brainteasers WAUTOMATIONDIRECT Does your dog bark by Chip McDaniel AutomationDirect While commissioning a systems integration job in H olland several years ago a co worker and I left the plant to get some lunch A road side concession stand a few blocks away had been recommended so we walked As we rounded the last corner we noticed a dog chalned to a tree beside the concession stand and more importantly he noticed us The dog began barking immediately and kept barking as we walked up the street and while we were standing in line to be served
45. grade components such as W indows based computers PLCs and D CS equipment are serviceable by a wide group of experts and consultants good news for those hoping to work in the utility market as well as for the utilities who are looking for more reliable and cost effective solutions Feimster feels that the grid will have to make further 6 9 EB e s e e s e 2 e s Aut omation Notebook Autumn 2004 Issue Two moves in the direction of fully automated controls as well These systems must become fully automated and remotely monitored H umans have the capacity to do only so many things at once not to mention thefact that problems can occur within fractions of a second and originate from hundreds of miles away he says O pportunity Abounds M odernizing the grid is going to require huge investments of time money and technical talent Engineers and systems integrators will no doubt play an important role in modernization D avid M eyer of OETD says Technical experts need to do everything they can to find out what s going on in their geographic region Regional transmission planning is a critical part of the solution Regionally where do we need new capacity W hat are the relevant technologies Getting information from the appropriate RT O regional transmission organization is a good first step advises M eyer Clark Gellings vice president of power delivery and markets for EPRI also sees
46. he master O ne feature that is particularly useful is the alarm history on the EZTouch panel Future planned expansions of this facility will be simply and easily added to our system network Aluminum anodizing system controlled with help from D2 260 PLC system and EZText panel by CR Williams Robo Systems Our system controls aluminum anodizing T he operator uses an EZ Text panel to enter the size of the job and the desired thickness of anodizing The D 2 260 translates this into the neces sary current voltage and time profile required to produce the desired result and controls a 300kW SCR switched power supply that delivers the anodizing current to the workpiece Since the optimum waveform has both short term lsec and long term min compo nents and needs precise control over two orders of magnitude 10A to 1000A the floating point math capa bilities of the D2 260 are used quite heavily The environment is extremely noisy electrically because of the 300kW SCR phase angle switching so the design of the grounding and shielding as well as software filtering were very important to the success of the project In addition to the standard PLC on off inputs and outputs analog inputs and analog outputs are used as part of the monitoring and control process 15 Sav A good thing just got better AUTOMATIONDIRECT is now offering Check out our Marathon motor and DURApulse drive combos and start saving
47. he pump s fluid flow may be more appro priately matched to the requirements of the user Reducing motor and thusfan and pump speed versususingdampersor valves utilizes power more efficiently thus improving system efficiency M achinery or conveyors become more efficient as they operate at optimal speeds Also motors operated by V FD sare not adversely affected by inrush current as are their line started counterparts T his high current typically six to seven times full load causes more stress on the endturns of the motor than the program controlled ramp up of aVFD which upon startup acts much like a soft starting device Asa result of lower mechanical insu lation stresses if you installed plexiglass in the motor s endbell you would actually see physical movement of the endturnsin a motor that was line started the insulation life of the motor is Automation Not ebook Autumn 2004 Issue Two lengthened when operated with aVFD W hat is the history behind the Blue Chip XRI product The Blue Chip XRI motor line was originally developed to meet the efficiency and performance demands of the chem ical process industry Companies like Dow Chemical were among the first customers to recognize the important role of energy in the production of their products and demanded that motor manufacturers improve the efficiency and life of their offering Through extensive cooperative engineering research and development M arathon Elect
48. hould have been applied in case of a breach W hether you have a small indus trial 1 0 system that forms the guts of a packaging machine a data acquisition and control system for a pilot plant a PC PLC based control system or a distributed control system you can t afford to take chances with security H ackers bent on outright destruction may surprise you with their knowledge of PLC DCS programs and networks And just because you may have a propri etary PLC or DCS or run aUNIX or Linux box you re not guaranteed secu rity unless you take some initial steps As a first line of defense you need to know where the attacks are coming from T he disgruntled employee Clarence is the model employee Loyal courteous an astute problem solver patient efficient and innovative But lay him off due to downsizing or outsourcing and he could be a threat to security W hat if thel T department kills his email box almost instantaneously with his layoff but no one thinks to remove hisF TP logon kill hisT ELN ET logon to the data acquisition system shut down hisVPN connection and kill his remote dial in W hat about the wire less connection Has it been secured You don t need to provide hot spots for disgruntled employees Let Starbucks do that Once you ve removed Clarence from all possible logon and database lists make sure his ghost doesn t return via a backup restore operation Check that his logon has also been removed from
49. ible locations Keep looking www automationnotebook com 3 1 Program EZIO operator panels in minutes 1 Jame 2 Configure a Write to Panel Burncr PID Chanber Temp iy iy Ta One of the most feature packed panels is also extremely easy to use Fa igp kurir ima s Create a project by Connect the cable to mae NN selecting PLC type leta _ the panel and download te and panel type PB seis 4 se 7 your configuration o JE zm A om H jf ot SFEEF a Rabel MI i 5 m lil i io mm ee EL EZIO Wiko or A dl Mm mij dest ead ne a a i i kr TENT j ee ee ee 7 _ o From the objects menu aE Li lt lt _ gt select an object fill in M d the dialog boxes then place and size the object on the screen EZTouch configuration software for EZTouch panels comes with a large assortment of high speed vector based objects and also features built in Symbol Factory with over 2 000 symbols PID faceplates and line graphs Pushbuttons and indicators e Meters and bar graphs e Multi state indicators and alarm history Radio buttons and step Switches 0 Numeric entry and numeric display Multiple text functions Dynamic and multi state bitmaps Recipes and thumbwheels Analog and digital clocks Bitmap buttons and more Available in 6
50. igh and low values that fall below and above the actual measured raw values we take the raw analog input signal and divide it by the unit number 409 This gives us the lookup table low offset value We will add oneto this number to obtain the high offset value T hese values will be used to index the lookup table See Ladder example 2 Ladder Example 2 Divide the raw analog value by the 409 max analog counts divided by 10 The result will be the low and high offset SP1 Raw Analog Value Non Linear 0 4095 BCD V2000 Lookup Table Low Offset Binary V3100 Lookup Table High Offset Binary V3101 All pointer addressing in D irectLogic PLCs is done as a hexadec imal eguivalent of an octal V memory address In other words take the octal address for example V 2000 drop the V from the front of it and change to octal 02000 and convert to hexadec imal octal 2000 hex 400 If just thinking about this makes you dizzy you can use the Windows calculator in scientific mode to perform the conversion Also there is a document on the Technical Support section of the AutomationD irect com Web site that can help you with the data types as well It can be found at http support automationdirect com docs an misc 013 pdf We will take the starting V memory address of our table V 4000 and convert it to hexadecimal 800 N ext add the offsets which were created above to get the actual address pointers
51. ixed rack No matter what your control system architecture Terminator I O can be part of your field termination network Terminator I O combines your control system I O points with their field terminations in one package Add it to existing PLC systems to reduce panel space and cost For distributed control applications install Terminator I O nodes close to field devices for faster and more efficient wiring and troubleshooting Or use Terminator as low cost field I O for your PC based IE 6 8 control system Terminator l O was designed by Koyo a Rg o moduN trusted name in control technology since 1983 Integrated Serial Port on I F Modules NO Terminator I O features YA a a mA w IWAN 54 SW DeviceNet evice NEW T1H EBC100 Ethernet interface offers 10 100 MB network 4 4 nja 0 speed and MODBUS TCP IP protocol support te Ethernet Discrete starting at 53 and analog modules starting at 261 ease 4 that connect to network interface modules via plug together I O bases with integral terminal blocks ACor DC power supplies and local expansion for larger 1 0 drops High speed counter module for simple stepper servo control 289 Eight and 16 channel I O modules AC DC in AC DC out relay out and analog in out E Three row Terminal Blocks Standard YES sa Optional on Flex1 0 utomationD irect has launched the SureStep family of l products a new open loop stepping system that provides simple and
52. l GFK 1504D GE Fanuc Series 90 Micro PLC User s Manual June 1998 GFK1065F prices from GE Fanuc Automation US Pricing Guide 8 6 01 OPTO22 SNAP 1 0 Modules Data Sheet Form 773 990204 prices from OptoExpress catalog www optoexpress com online store 02 05 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 Call or go online to request your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com WAUTOMATIONDIRECT One machine can do the work of fifty ordinary men No machine can do the work of one extraordinary man Elbert H ubbard 1856 1915 10000 4 me SR IN WK i Product Snapshots Press Releases VAUTOMATIONDIRECT module provides high performance low cost Ethemet link Cumming GA August 15 2004 The new T1H EBC100 module provides a high performance Ethernet link between Terminator I O and any connected client hardware or software system for applications in PC Control PLC Remote I O or data acquisition Terminator I O is a distributed Field I O system that combines the I O points with their terminal blocks into a modular package to save cost and panel space The TIH EBC100 module supports TCP IP UDP IP DHCP and IPX at 10 100 Mbps It also supports MODBUS TCP IP protocol the most widely used open protocol in
53. lers By installing either temperature or analog I O cards into any of the four available D L06 option card slots and taking advantage of the snap in LCD display and PID loops built into the CPU this application can be accomplished with just the PLC and its connected devices Add an Ethernet module and the PLC can also double as a data acquisition node providing connectivity to any larger plant LAN or WAN information system Connect a dial up modem to the secondary serial port and this PLC can be the controller for an RTU aspart of alarge SCADA system And if your application reguires motion control use the inte grated high speed I O to connect a simple stepper system or install a high speed counter pulse output module connected to a servo drive to accomplish a variety of open loop motion control applications M any of these capabilities can be found in new PLCs from most of the PLC vendors around the world PLC users benefit greatly from increased performance and scalable control capabilities there are fewer controllers and control programsto maintain and programs can be reused for multiple applications T his allows guicker installation and easier service of PLC systems resulting in significant savings in the initial capital expense of hardware and software and savings in engi neering time for system integrators O EM s and the end users they serve In the next installment of PLC Speaking we will explore the changes in traditional a
54. mounting controllers terminals motor controls and more ZIP INK onnection ystems AUTOMATIONDIRECT s ZIPLink pre wired PLC cables easily connect 1 0 modules to connector modules for fast easy terminations Connector modules available include 75mm or 155mm high One meter lengths One meter lengths 1492 W6 102010 30 04 36 2 N 203 O 50 32 5127 1492 WTS3LP 157851 N 27 15 85 6 N 12 60 O 3 09 737 199 DR1 51450 08 01 73 3 B 16 74 0511 84 Bs 12 00 da Capi IKA Aves ofl amra CA USA JE viri eur Rigid PVC Duct e UL 94V 0 flammability rating e Sizes from 1 2 x 5 8 up to 6 x 4 e Two meter lengths e Cover included e Single piece quantities available Full line of accessories Flexible Duct e Sizes from 1 2 to 1 1 2 square Wire Duct Sample Pricing Duct Type and Size Part Number Price Rigid 2 25 x 2 25 2M 12 pes T1 2222G Rigid 3 x 4 2M 4 pcs Ti 3040G 98 75 Rigid 4 x 5 2M 4 pes T1 4050G 152 50 Flexible 1 x 1 x 19 7 36 pes DN30AG 189 00 feed through AC or DC relay fuse LED diode and more e Cables in 0 5 1 0 and 2 0 meter lengths For a complete listing of enclosures terminal blocks wire duct accessories and prices visit our website at www automationdirect com Call or go online to reguest your FREE 1 600 page catalog 1 800 633 0405 www automationdirect com m VAUTOMATIONDIRECT
55. n index values for their product category in a customer satisfaction survey conducted by Control Engineering magazine in 2004 To help address customer guestions about inverter duty motors and motor drive applications we talked to Tom M atyas AutomationD irect s Drives M otors and M otion Product Manager about M arathon s history of product development and recent advances in motor and drive technology W hen did M arathon Electric start to develop inverter duty motors About twenty five years ago customers started to approach M arathon Electric with applications that required motor speed to be altered with variable speed devices known as drives or inverters Since many of the original drive 18 manufacturers were located in the upper Midwest and M arathon is headguartered in Wisconsin the company became a logical and convenient location to help develop those manufacturers products Marathon accommodated these manufacturers by providing outstanding test facilities for then to test thar products with M arathon motors T herewardswere twofold drive manufacturers saw how their products func tioned with M arathon motorsand M arathon engineers learned how those drives affected their motors T his led to several generations of drive compatible motors that are now named Blue M ax Black M ax Blue Chip KRI and microM AX With the advent of the IGBT drive several new parameters were introduced to the motor Changes in
56. ncoder provisions included on the opposite drive end T he Blue M ax line offers constant torque Operation from 0 to base speed RPM on vector drives and constant H P operation up to twice base speed 143 256 frame size These motors are optimized for operation with IGBT inverters W hy was the microM AX motor developed Originally M arathon Electric wanted to develop a low cost replacement for Permanent Magnet DC PMDC motors Combined with low cost digital micro drives the microM AX provides exceptional performance throughout its rated speed range T his revolutionary design features up to a 1000 1 constant torque and 2 1 constant horsepower range rivaling much more expensive variable speed motors Other design features include linear torque characteristics superior starting torque up to 400 excellent torque to inertia and smooth low speed performance To ensurelong life M arathon utilizes their exclusive CR 2000 corona resistant magnet wire microM AX motors meet all applicable UL CSA and NEMA standards including NEMA M G1 1998 Part 31 In addition to initial acquisition cost savings mainte nance cost of ownership costs are virtually zero With no brushes or commutators to maintain the user can expect significant savings over the lifetime of the motor As an example the five year cost of ownership of a HP microM AX motor versus PM DC shows no brush replace ments as compared to 15 brushes 30 equaling 450 in Sa
57. nd non traditional PLC applica tions that these new lower cost and feature rich PLCs are accomplishing For this topic AutomationDirect has a customer survey on PLCs we d like you to participate in see www automationnotebook com plc survey Questions will be centered around the most popular PLC applications of today and the fastest growing newer PLC applications being brought to market If your company uses PLCs or is planning to use PLCs complete this online survey and be entered in a drawing to win one of five BO SE Wave radios hope you enjoyed this first talk on PLCs and look forward to your survey answers so we may Speak PLCs with you again M etcalfes theory states that the power of a network increases by the square of the number of nodes connected to it For example where X is the number of nodes the power of the network is X squared M etcalfe observed that new technologies are valuable only when large numbers of people use them Robert M etcalfe inventor of Ethernet and founder of 3C om Corp ae The most micro PLCs you can buy Both the DLO5 and DLO6 feature ractical wo b n sp La 24 lt a cards to expand your 1 0 and applications ACInorDCIn DCOutor DCIn Out 06 PLC Thermocouple Current In z k RTD starting at 199 ey Out Voltagein Combo Voltage In Out Se oe Combo Current In Out 20 inputs 16 outputs Expandable to 1001 0
58. ng RFID marking at the pallet and case level for product receipt at Wal M art distribution centers by January 2005 The D epartment of D efense followed shortly with the announce ment of their own RFID policy for received materials to be applied to the lowest possible piece part case pallet packaging also by January 2005 As the suppliers to these two mammoth customers begin to implement the technology it will naturally proliferate to other customers and manufacturers R egardless of the cost and technology hurdles remaining these initiatives have greatly increased the likelihood that RFID use is inevitable in a wide range of industries including food beverage and particularly pharmaceuticals To gain a basic understanding of RFID technology and applications visit www rfidjournal com or www aimglobal org technologies rfid M any trade magazines have also covered the technology suppliers and applications in recent months including Control Engineering M odern M aterialsH andling and Automation World e e 9 e 3 10000000 Aut omation Notebook Autumn 2004 Issue Two User Solutions Application Stories Ever wonder how AutomationDirect customers are applying their products Check out some of the application stories we ve collected and you ll see that AutomationDirect products are used in a wide variety of applications across many different industries D2 250 PLC PID loops control pumps in
59. ng technology with selectable step sizes of 400 steps per revolution divide by 2 1 000 steps per revolution divide by 5 2 000 steps per revolution divide by 10 and 10 000 steps per revolution divide by 50 A standard 32 V D C 4 amp power supply completes the Profibuse K o a LLC NEEEEKEH Modules start at 136 and include an on board RS 232 4 serial port ee ie KAM oer ern Coe eee EEEE EEE NELL DEEE AHE LU KME EA TT eee ee Tere ee SGPC PTT PSE PPR eee hoe hs ey PRG Ge Pee Se pe With Terminator 1 0 AutomationDirect offers true Ethernet OPC server software is available starting at SureStep line T he power supply operates at least two SureStep stepping systems of any size with an auxiliary 5 VDC regu lated supply to facilitate field termination I O on five of the most popular industrial networks at one half to one third the price of comparable field 1 0 products 129 This server is a great fit for data acquisition or monitoring applications AutomationDirect YS Competition DirectLOGIC PLCs and stepping motor drive interfaces Prices for the new SureStep motors range from 19 to 99 The SureStep microstepping drive is priced at 149 and the power supply is 99 WY mai IFS versakaxijO SNAP EEC ferminator 70 YES NO Modbus NO DeviceNet 43 Ethernet Profibus s O n D NO angen uit a DeviceNet Modbus and manually attach ed 1 0 a in a f
60. noying to put up with frequent W indows updates especially for servers because there s never a good time to restart a server after installing the update if you haven t updated lately you re inviting problems It s probably a good idea to check with your HMI or DAQ software supplier before you apply updates just in case there are any issues Updates also mean Service Packs which are up to Version 4 on Windows 2000 and Version 2 soon to be released on W indows XP If an HMI must be connected to the Internet virus protection is manda tory and you might also want to consider the use of Spybot Search amp D estroy Ad aware or similar tools to search for and eliminate any commer cial soyware adware that may exist on the computer C hecking the task list and running a sniffer program like ActivePorts Isa good way to see what s going on behind the scenes and what might be affecting your performance Take a snapshot of the task list ALT Print Scrn paste it into a Word docu ment and print it Check your task list regularly to see if any new unautho rized tasks or programs are running which might be viruses spyware adware etc A good way to prevent spyware and adware from getting installed is to make sure user accounts don t have any installation privileges D on t give opera tors any more privileges than necessary to get their job done If you must use Internet Explorer keep its security settings very high
61. nufacturing reoorts Currently the electricity sector is laboring under an inconsistent and conflicting set of federal and state rules and a highly uncertain regulatory frame work Due to this regulatory ambiguity most utility companies have limited their investments until the market structure is more clearly understood M agnifying this lack of investment is the fact that the pressures of cost containment have essen tially stifled and deferred needed infra structure investment for at least two decades T he statement encourages both the Bush and Kerry presidential campaigns to include modernizing the electricity infrastructure as a top priority The technology portion of grid transformation depends on developing innovations that enable digital control of the power delivery network integrated electricity and communications for the user transformation of the meter into a two way energy information portal inte gration of distributed energy resources into the network and a robust advanced power generation portfolio including coal refining according to EPRI How much will it cost A rough estimate calls for 100 billion in public and private investment over the next 10 years Benefits are expected to outweigh costs by a 10 1 ratio says EPRI Engineers Systems Integrators Weigh In Engineers and systems integrators working in the field have their own views on what s happening with regard to modernizing the grid Steve Dro
62. on master SUBR Analog reading from the low calibration master V3002 OUTD Reading from high analog master reading from low analog master V3014 LDR Actual length of high calibration master V3004 SUBR Actual length of low calibration master DIVR Reading from high analog master reading from low analog master V3014 OUTD Multiplier that will be used to convert counts to inches V3010 Figure 1 from the device being measured is stored in register V 2000 See Figure 2 Some of the advantages of this calibration procedure are Because the user chooses the cali bration points calibration masters can be at any length Calibration masters no longer need to be made to a specified predetermined length If a specific range is the most crit ical the calibration can be done at that specific range In the example above If the most critical readings are between 3 5 and 4 2 inches of length the cali bration masters can be approximately 3 5 and 4 2 inches In this way calcu lating the straight line over the critical range minimizes any non linearity in the system and provides the most accu rate readings in the critical range By displaying the actual calculated length and the analog counts on the Operator interface anyone who desires can follow along with the PLC and www automationnotebook com On SP1 LD Analog reading counts from device being measured V2000 SUBR Analog readin
63. onnections which rely more heavily on traditional text screens and audio W hile the site makes it easy to gain a general overview of the DU RApulse drives it also provides links to details such as technical specifications and the complete product manual It is anticipated that as more tech nical information is added the site will eventually become a technology center on the topic of AC drives In any video production there are always bloopers before you get it just right Visit www durapulse com s N ow W hat page and see if you can find the smiley blooper icon to view some of these moments RFID will affect many manufacturers and packagers Radio frequency identification RFID has become one of the most visible issues in manufacturing and packaging in recent months At its simplest RFID is a generic term for technologies that use radio waves to automatically identify products to which a special tag has been affixed To identify or access Information about the product an RFID reader typically communicates with the tag which holds digital information in a microchip While RFID technology has been available for years It has been too expensive and too limited to be practical for most commercial applications As both the capability and cost of the tags has improved RFID is being viewed as the solution to some of the problems associated with bar code identification systems In mid 2003 Wal M art announced plans to begin usi
64. p the city water system at a more constant pressure Setpoints are entered with a touch panel and the pressure is displayed as well T he system controls the startup sequence releasing the well flow to a drain and slowly cutting into the system to prevent a pressure spike on startup It also controls the shutdown to prevent a pressure dip System pres sure Is maintained with a PID loop in the D 2 250 processor DL06 PLC and EZTouch panel help move cementat bulk handling facility by Jeff Bailey Ozinga Bros Inc We recently installed a bulk cement handling facility The facility offloads cement from river barges and pneumatically conveys the powder into a massive storage dome and truck loading facility The concrete dome which can hold 30 barge loads of cement powder was erected using an inflatable air form system AM ODBUS network of four D L06 PLCs controlled by an EZTouch Operator Interface outloads the cement from the dome A 4 20 maPID loop implemented in one of the DL06 processors controls the soeed of two hydraulically driven sweep augers An analog radar sensor monitors www automationnotebook com the cement level in the truck loading Silo All three primary functions are graphically animated and displayed on the EZTouch panel The supervisory master DL06 controls the pneumatic conveying system and acts as the communications hub for the slave processors Each processor runs local functions independent of t
65. ple 5 shows how to calculate the raw unit values based on the table offsets that were calculated in Ladder Example 2 Continued on next page 25 Tech Thread Indirect Addressing Cont inued Ladder Example 5 Convert the calculated low and high scale values for the raw units into a real number format 9 Lookup Table Low Offset Binary V3100 FREE 1 600 page Catalog K ke rices p IU ISI On o Industrial Automation Notebook Autumn 2004 Issue Two Technical Review Common Questions about Control Transformers by Keri Schieber Managing Editor hat is a control transformer A control transformer is an isolation transformer designed to provide a high degree of secondary Total Inrush VA VA sealed VA inrush or Total Inrush VA VA sealed VA inrush 5 If thenominal supply voltage does not fluctuate more than 5 then reference the 90 secondary column in the manufacturer s Regulation Data Table for the correct VA rating If the supply voltage varies up to 10 the 95 secondary voltage column should be used to size the transformer controls Get your FREE 1 600 page catalog with over 5 000 high quality industrial automation ONA components with helpful selection guides w calibration maser specifications and full price list low calibration master um PLCs Operator Interfaces AC Drives and Motors e Sensors Motor Controls e Pushbutton
66. pplications And our two year warranty and one relay e American customer and allows ZE ge AA a three years if you purchase and install an input e Built in RS 485 MODBUS communications you to configure the drive setthe speed startand stop l 31 ZSEE 1 273 Optional Ethernet communications the drive and monitor critical parameters for your jp seems Y549 1 551 E205 line reactor IS the best IN the industry Optional configuration software application The internal memory stores up to four Pee Y552 1 941 E206 Black Max UL CE listed complete programs that can be transferred to any GS3 2025 ieee 2 399 za vector duty DURAPULSE drive GS3 2030 680200 3 689 GS3 2050 _ 4 574 Motors Motors Pkg 100 hp Total if Our ap a OO hp drive 460 VAC H pa Price i i Price Sj eo Wr 25 ne ee kel M us Meni uss ara Fd vs HEROD Y535 Y536 464 471 o 5 i XRI ultra 0 di CU a 5 919 91 9 918 NEKI Y364 449 230 VAC 460 VAC E 42P0 Y368 569 Y551 606 high Part Price Part G58 43P0 1999 644 weal deski efficiency Number US Number p press ap US ip
67. residential water system by Peter Carman Wyoming Controls Weused PID loopsin the D 2 250 CPU to control three pumps and maintain pressure in a residential water system T he flow demand varies from zero to 250 gallons per minute The pumps all have variable speed drives with the speed reference and run commands coming from the 250 CPU At low flow one pump runs alone as needed to maintain the pressure Asthe flow increases the other pumps are brought on either in tandem with the first or at a constant flow rate T he flow from each pump has an upper limit if the total flow demand exceeds the combined upper limits the pressure will fall The result is that each pump can Operate in an optimum range on its pump curve and a widely varying flow can be delivered and the pressure is maintained very closely T he operator interface is a color touch screen that displays the pump status flow rates and system pressure All the setpoints for pump on off and associated time delays are easily accessible to the system operator D2 250 CPU maintains water pressure for city water system by John Neiswanger Industrial Electronics We created a water pressure controller for a local city water system We used a pressure transducer to feed a water pressure signal into the DL205 PLC system analog card The output from an analog card is used to vary the speed of a 75 HP well pump controlled by a variable freguency drive to kee
68. ric has developed a line of premium efficiency motors that meet or exceed the rigorous requirements of all major processing manufacturers T hese industries include petrochemical mining pulp and paper pumping and automotive The Blue Chip XRI Ultra H igh Efficiency motor incor porates an all cast iron frame and end bells that provide the necessary strength and corrosion resistance for the most demanding industrial applications They also feature 100 copper windings that offer lower resistance and lower temper ature rise for higher overall efficiency Low loss electrical grade steel laminations and longer stack lengths in the rotor and stator reduce electrical losses and improve heat transfer by lowering flux density and increasing cooling capacity T he Blue Chip XRI family boasts one of the highest overall efficiency levels in the motor industry and is inverter rated at 20 1 constant torque XRI motors meet NEM A Premium efficiency levels have a 1 25 service factor through 40 HP 1 15 above and provide the eXtra Return on Investment XRI expected of ahigh efficiency motor Are these features incorporated in the Blue M ax product line In addition to the features of the Blue Chip motors the Blue M ax motor line was engineered with several premium components that stand out from the competition They include the MAXGUARD Class H insulation system a patented low stress winding design normally closed thermo Stats one per phase and e
69. rol signals by simply moving the module s range selection jumpers AC DC relay modules are also used for both generator and dam control Two operator interfaces and a Windows NT based PC running the LookoutDirect SCADA HMI software package complete the system System operation In the automatic mode the PLC can start stop and operate the generator via two PID loops that control startup and synchronization of the turbine Changing the generator gate position varies the flow of water to the turbine and thus the generator s speed freguency To bring a generator online it must first be synchronized with the line frequency of the power utility T nefirst PID loop slowly increases the generator speed until it reaches 90 of the setpoint at which point the logic switches to freguency control O nce online the generator s power output is varied by changing gate position To complete Level 2 control North Fork Electric then installed the dam control system T his system controlsthe eight canal gates located at the dam which regulate the flow of water downstream to the turbines T he operator enters the required gate position setpoints using a color touch panel connected to the dam control s master PLC in the control room Data is transmitted to theslave PLC located at the dam via 900 M H z radio modems T he slave PLC monitors individual gate posi tions using proximity switches that count teeth on the drives gears and moves the gates
70. rol transformer be used in reverse power factor A Yes a control transformer can be used in reverse Gompany Total steady state sealed VA is the total amount of VA H owever keep in mind the output voltage will be less a E R that the transformer must supply to the load circuit for an Wa rating due to the compensation factor of the high calibration master Mali eles extended length of time Calculate by adding the total Mae tii steady state VA of all devices in your control circuit The City State Zip operating VA data for the devices should be available from O Can a control transformer regulate the output voltage Phone Fax the manufacturers A No acontrol transformer will not regulate voltage We are now ready to perform the analog calibration T hisis covered in the FY article on pages 28 and 29 Implementing a PLC Calibration Routine to Ensure Accurate Instrument Readings For other example ladder logic programs please visit www automa tiondirect com s tech support home page and click on example programs Follow the instructions on the page to view zipped files N ote D irectSoft soft ware is required to view the sample programs If you do not currently have DirectSoft you can download a free demo version at http support automa tiondirect com demos html 26 Business Type L End User M OEM CJ Integrator CJ Other Primary Product Interest Send me your monthly e mail newsletter LI email I need a full ca
71. s 11S shut off as default Software will become available to scan computers connected to anetwork for viruses patch updates and illegal open ports before they will be given full access to network services W indows Rights M anagement Services will control email destinations protect sensitive files and safeguard Web portal content Outlook Web access will preauthenticate all users ISA Server 2004 firewall protection will make email safer to outside employees Tech Thread Indirect Addressing WAUTOMATIONDIRECTE Using Indirect Addressing in a PLC to Scale a Non linear Analog Input Signal by Richard Palmer AutomationDirect ndirect addressing or pointer addressing as it is called with Koyo PLCs is an addressing mode found in many processors instruction sets that specifies a register that contains the effective address Accessing the operand reguires two memory accesses one to fetch the effective address and another to read or write the actual operand Indirect addressing has many uses the most common of which is lookup tables You could perform numerous compare state ments for the same function but lookup tables can cut your programming time and number of rungs considerably For instance finding the number of gallons in a horizontal tank is a fairly long and complex math process that can take up a lot of scan time It certainly isn t a linear equation as seen in Figure 1 The d
72. s and Lights Enclosures Connection Systems Communications e Power Supplies and Protectors Relays voltage stability regulation during a brief period of overload condition also known as inrush current Control trans formers are also Known as machine tool transformers indus trial control transformers or control power transformers H ow do select a control transformer Selecting a control transformer requires that you have a aa first hand knowledge of the specific application for greater than the value obtained in Step gt the transformer and that you understand some basic terms Frequently asked questions used in the selection process By using the following Q When you calculate the VA requirements of a trans 6 Using the manufacturer s regulation data table select the appropriate VA rated transformer a With a continuous VA rating that is equal to or greater than the value in Step 3 b With amaximum inrush VA equal to or Lookup Table High Offset Binary V3101 Process controllers information you will be able to select the correct control transformer for your application To select the proper transformer you must first deter mine three characteristics of the load circuit T hey are total former do you use the primary or secondary voltage A T he secondary voltage is used in calculating the VA Name Title steady state sealed VA total inrush VA and inrush load Q Can the cont
73. t which a transformer can deliver for a specified time at its rated secondary voltage and rated frequency without exceeding it s specified temperature rise For additional Information on control transformers visit the Technical Support Applications and FAQ section of the AutomationD irect web site Be sure to read the application note on control transformers Fuse sizing for primary and secondary windings www automationnotebook com 2 7 FYI Calibrating PLC Analog Signals VAUTOMATIONDIRECT Implementinga PLC Calibration Routine to Ensure Accurate Instrument Readings by Gary Multer MulteX Automation hy calibrate M any applications call for a means to take accurate analog measurements Force pressure electrical current lengths positions and other analog values that are measured must be done so with a degree of accuracy Factory and lab personnel use calibration procedures to ensure that eguipment is reading accu rately If the readings are not as accurate as required a calibration procedure should allow for the implementation of a correction factor Personnel operating the equipment can perform their jobs more readily if the measurement system can easily be checked for accuracy and calibrated Ideally the process would be transparent to operators who do not need to understand the details of the Operating system and only need to see and understand the measurement results reoorted by the equipment
74. talog C RaQWASI ynar FREE csislog today I need a catalog on GD with demo software LI Fax to 770 889 4212 or Mail to 3505 Hutchinson Road Cumming GA 30040 or Gall 1 800 633 0405 or go online at www automationdirect com he cmon acres way in huy irulredrial 1x nrrzila WAUTOMATIONDIRECT AEREE DILI ili T he inrush VA is the amount of VA that the transformer must supply for all components in the control circuit that are energized together Consideration for the start up sequence may be required Inrush VA data should be obtained from the device manufacturers The inrush load power factor is difficult to determine without detailed vector analysis of all the control components In the absence of such information werecommend that a 40 power factor be utilized Once the three circuit variables have been determined follow these six steps to select the proper transformer 1 Determine your primary supply and secondary output voltage requirements as well as the required frequency i e 60 H Z 2 Calculate the total sealed VA of your circuit 3 Calculate the inrush VA by adding the inrush VA of all components being energized together 4 Calculate the total inrush VA using one of two methods O utput voltage is a function of the coil s turn ratio times the input voltage O Can you explain the VA or Volt Ampere O utput rating A TheVA or volt ampere output rating designates the outpu
75. ters enhanced monitoring capabili ties enhanced operator training and increased its vegetation management We ve foot patrolled all 11 000 miles of our high voltage transmission lines and have cleared any potential problem trees Easement rights are also being enforced to assure adequate clearances Beyond these immediate issues 7 Hours after blackout 8 15 03 satellite image courtesy of NOAA DMSP and other industry and government spokespersons the most important issue is to make reliability standards manda tory and enforceable with penalties for noncompliance The U S Congress must enact these reliability provisions to make them stick with industry something many folks both in and out of govern ment have wanted for years We need legislation says M eyer but we have other things in place to work with until legislation gets approved www automationnotebook com NERC is in the process of restating its reliability standards in a more specific form making them easier to follow and enforce Final approval of these new stan dards is expected in 2005 Other stan dards are also in development according to M eyer T hese include national guide lines for vegetation management as well as real time operating tools that will allow for wide area visualization and give earlier warnings about arising problems Grid of the Future M oving from an aging electro mechanical grid to a fully automated electronicall
76. th prices starting at 189 00 Carbon steel fiberglass stainless steel and aluminum subpanels as well as a line of accessories round out the new non metal enclosure offering Marathon Motors line extended Cumming GA August 15 2004 The Blue Max M arathon motors Is now available with a shaft mounted encoder The encoder 4 isa Dynapar model H 535 and requires a 5 26 VDC power source It has a line count of 1024 pulses per revolution PPR and a differential line driver output A 10 pin connector is supplied with the TEFC models and a junction box is provided with the T EBC models Also new are lower horsepower versions of Marathon Blue Chip XRI motors The Blue Chip XRI motor line previously included 40 100 H P models and is now available in 15 20 25 and 30 HP versions New lower HP Blue Chip XRI models start at 839 2 pole models added to supplementary protectors line Cumming GA August 15 2004 2 pole versions of the Cutler Hammer WMS line of supplementary protectors are now offered in addition to existing 3 pole and 1 pole models The 2 pole protectors are available in models ranging from 6 60 ampsand are priced at 14 WMS Series protectors are UL1077 recognized for applications where branch circuit protection is not required or is already provided The 2000 series of thermal magnetic devices protect against short circuit and overload
77. transmission lines to 131 million customers T he U S spends 247 billion on electricity each year and the grid s total asset value is estimated at 800 billion According to industry experts including OETD the grid is reaching 8 electricity needs While the country is moving quickly into the digital information age increasing its need for reliable electricity the electro mechan ical grid is aging T he existing infrastruc ture of wires transformers substations and switchyards has been in place for 25 years or more According to OETD a number of factors are impacting grid performance including aging equip ment transmission bottlenecks deregu lation and regulatory change These factors have combined to discourage private sector investment in grid upgrade especially regarding new trans mission and distribution technologies Why is it so difficult to reliably operate the grid First electricity flows at nearly the speed of light and isnot ableto be stored in large quantities economi cally speaking It must be produced the moment it is used Second without expensive control devices AC current flow can t be regulated like a liquid or gas So it flows freely on all available paths according to the laws of physics These two factors make reliability a complex challenge In order to ensure reliability NERC North American Electric Reliability Council and its 10 regional reliability councils focus on st
78. trols and perform distributed independent control at the dam and each of the five turbine stations Each I O control node would replace the old equipment in the existing control cabinets and be networked to the central control room Systems integrator and vendor selection Lockhart Power contracted North Fork Electric a provider of hydroelectric products and systems integration services in Crumpler NC to lend their expertise to the reno vation N orth Fork Electric proposed a 3 tier solution Level 1 included new hardwired controls for manual operation of the system Level 2 included PLC based control of the dam and generators in an automatic mode Level 3 provided PC based redundant control and monitoring from a central location and also supplied connectivity to the plantwide Ethernet network System components The system consists of seven DL205 micro modular PLCs using D2 250 CPUs with built in PID functionality Each of the five systems for generator control includes analog I O and an Ethernet communications module T he remaining two PLCs are configured in a master slave arrangement and 20 control the dam gates located upriver from the powerhouse via radio modems To reduce maintenance costs North Fork Electric selected DL205 1 0 components to maxi mize commonality among all systems T he identical analog output modules used on the generators configured for 10 VDC can be configured for the 0 5 VDC dam gate cont
79. uilhet president and founder of Sustainable Automation LLC Boulder CO designs and manufactures controllers for indi vidual power system components and Supervisory controllers for complete distributed power systems particularly those incorporating wind energy The company also provides custom control solutions for a variety of 10 Area affected by the blackout lt A si Power Grid of North America industrial manufacturing and process control applications Drouilhet says that distributed generation such as customer owned wind turbines and natural gas fueled engine generator sets is already cost effective in many cases In addition distributed generation could make the power grid more robust T he problem is that many utility companies see distrib uted generation as a threat so they require costly interconnection studies and impose exorbitant standby charges which are unfortunately often approved by public utility regulatory commissions T he result is far fewer distributed power systems than there could be he says D rouilhet adds that the situation varies from state to state utility to utility Progress is being made in renew able energy and if the inhibiting factors were removed results would appear even faster he adds Small victories are indeed taking place As reported in the August 6 issue of W ind Energy Weekly The Massachusetts Department of Telecommunications and Energy issued an order
80. uncil Laid off and ticked off Boden sought his foul revenge Using a stolen laptop and two way radio he connected wirelessly to the plant s control system and issued a few lines of code O ver the course of several weeks he presided over the release of hundreds of thousands of gallons of raw sewage Into nearby waterways Davis Ohio January 2003 The DavisBesse nuclear power plant s process computer and Safety Parameter Display System shut down for several hours T he culprit T he Slammer worm inadvertently released by a contractor who established an unprotected computer connection to the corporate network through which the worm reached the plant network and SQL server Upon investigation D avis B esse discovered that plant engineers weren t even aware of the Microsoft patch released six months earlier Fortunately the plant was off line so neither of the affected systems caused safety failures What is the common thread connecting these two examples Failure to act not after the incidents occurred but ahead of time to prevent them from happening in the first place In the first situation Boden s ability to log onto the system should have ceased the moment his position was terminated In the latter case W indows security patches were not 22 installed when they were issued Even though the plant SQL Server may not have been attached continuously to the enterprise system operating system OS updates and patches s
81. vings no commutator maintenance as compared to 5 commutators 100 equaling 500 in savings and energy Savings 0 8 K W of 161 W hile thetotal physical savings iS approximately 1 100 the improved productivity is even more valuable Why has Marathon Electric developed an association with AutomationD irect M arathon Electric believes that AutomationD irect offers a unique approach and access to the marketplace through its Internet site and complete product support to assure customer Satisfaction and reliable product quality and service AutomationD irect has taken the time to extensively test and evaluate the M arathon Electric product offering to assure the reliability and compatibility of the Blue Chip XRI Blue M ax Black Max and microM AX products AutomationD irect s D U RApulse and GS2 lines of AC drives have been tested at M arathon s state of the art lab facility also to ensure interop erability and to validate performance requirements T he entire line of M arathon motors offered by AutomationD irect carries a 3 year warranty complies with UL requirements and NEMA standards and carries the C E mark T hese factors combined with the unique features of AutomationDirect s DURApulse drive line make AutomationDirect the ideal source for serious drive application customers M arathon Electric also realizes that AutomationD irect can reach those customers who understand the requirements of their application and can indep
82. y controlled system that supplies affordable clean and efficient energy sounds like a dream Yet little by little with advances in technology and the right people to install it the grid will slowly morph into its future self OETD svision of the new system called Grid 2030 envisions a fully automated power delivery network that monitors and controls every customer and node ensuring two way flow of informa tion and elec tricity between the power plant and the appliance and all points in between T he grid will use distrib uted intelligence broadband communications and automated control systems to enable real time market transac tions and seamless interfaces among industrial plants and the people buildings generation facilities electric network EPRI Electric Power Research Institute shares a similar vision ts 21st Century Transformation alms to stabi lize electricity markets provide for the public good protect the environment educate and empower consumers and unleash technical innovation EPRI seesa trilemma of economics politics and technology that needsto be synchronized 9 Cover Story VAUTOMATIONDIRECT Moder niz ing America s Electric System continued in order for progress to go forward No one can solve the trilemma alone according to EPRI and no simple solution exists Further a joint statement issued July 20 by EPRI and the National Council for Advanced M a

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