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Issue 9, 2007 - AutomationDirect

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1. OTE DnE L00 Cover Story Made in America New Product Focus AutomationDirect launches new line of current sensors Technology Brief Semiconductor breakthroughs promise smaller faster chips Feature Story Anti terrorist barriers help protect facilities ACUAMP current sensors help you monitor your process Panel mount or DIN rail adapter available for easy installation Quick response times as low as 100mS Current switches and 0 10V output transducers are self powered Multiple input range models offer flexibility in a single unit to reduce unique components needed Wide sensing range up to 0 200A models Our new acuAMP line of current sensors are an excellent way to monitor loads for power consumption or abnormal conditions From low cost switches to True RMS transducers we have a current sensor that will help you improve your process or make maintenance easier e ACT series transducers have jumper selectable current input ranges and industry standard 4 20mA or 0 10 VDC outputs ideal for remote monitoring data logging and alarming e ACTR series True RMS transducers combine a current transformer and true RMS signal conditioner in one unit for accurate measurement of distorted waveforms SCRs power supply and ballast input power e ACS series current operated switches offer discrete outputs for low cost status indication and alarming e ACSX serie
2. VWAUTOMATIONDIRECT www automationdirect com 1 800 633 0405 Wf ONLIN g the 1 value in automation Copyright 2007 AutomationDirect Cumming GA USA All rights reserved Automaton vote Look SYMMEL 2007 Tssye Mine Business Notes of Biotye s And Robots ing a focal Biofuels beco point of alternative fuels By Joan Welty AutomationDirect Biofuel can be defined as the process of converting organic based matter into burnable fuel as a replace ment for fossil fuel It is a renewable energy source unlike other natural resources such as petroleum coal and nuclear fuels The production of biofu els has been in active development for years most recently spurred on by President George W Bush who said in his 2006 State of the Union speech that he wants the US to replace 75 of the oil it imports from the Middle East with biofuels by 2025 One of the most common sources of biomass used to create biofuels is agricultural products Those specifically grown for use as biofuels include corn and soybeans primarily in the United States flaxseed and rapeseed primarily in Europe sugar cane in Brazil and One unintended consequence of the rise in palm oil in Southeast Asia biofuel production is the escalation of food commodity prices corn prices are rising as corn based ethanol production grows and there is concern that there is not enough agricultural production to support both the
3. WAUTOMATIONDIRECT new functionality such as Ethernet communication motion control and advanced algorithms into the existing scanner architecture while maintaining the familiar look and feel of PLC programming and the strengths in logic and control The result is PAC software generally designed to fit specific types of applications such as logic motion and PID but less flexible for custom applications PC software vendors begin with a flexible purpose programming language which provides very general in depth access to the inner workings of the hardware and works to incorporate reliability determinism and default Although scanner control architectures the structure normally provided to the PLC engineers can create programmer they are not inherent in PC control software This makes PC software flexible and well suited for that advanced structures programming tech complex applications require niques or system level control but more difficult for simple applications The first step for these vendors is to provide reliability which is often not available in a general purpose operating system such as Windows This action comes by using a real time operating system RTOS These systems provide the capability to control all aspects of the control system PAC extensions PAC concepts today also extend beyond simple I O by incorporating higher speed measurements and vision Many industrial app
4. turing dollar generates an additional 1 37 in economic activity Manufacturing also provides nearly half of all corporate taxes collected by state and local governments while funding more than 70 percent of the R amp D conducted in the private sector Facing challenge In its recent report the National Association of Manufacturers makes it clear that although U S manufacturing is strong it is continually being challenged on many fronts Manufacturers in the United States face unprecedented challenges ranging from rising energy and health care costs to a shortage of skilled production workers scientists and engineers warns John Engler NAM president One area where America s dominance is in jeopardy is our investment in research and development The U S presently accounts for 40 percent of all R amp D spending in the industrial world but the ratios are changing quickly and not in our favor because federal spending has fallen in the past 20 years In 1985 America invested 0 25 percent of the GDP into R amp D today it s only 0 13 percent Since World War II federal support for industrial research has been a key source of American innovation Automaton vote Look Symmer zoo7 Issy wre Jasinowski explains But R amp D spending is now half of its mid 1960 s peak when it was two percent of the GDP By comparison the United States Figure 2 Two thirds of manufactur
5. and limit alarm into one package Available in fixed core and split core models ACS150 switches are ideal for use in monitoring or proof of operation applications The self powered ACS150 is equipped with an adjustable setpoint range of 1 150 amps and universal solid state outputs and can be tailored to provide accurate and dependable digital indication of over current conditions for a broad range of applications ACS150 series current operated switches are UL cUL and CE approved and prices start at 63 The ACS200 series current operated switches are equipped with a choice of three jumper selectable input ranges so it can be tailored to an application and provide more precision in setpoint adjustment In addition to being self powered standard features include isolated solid state relay outputs multiple input ranges and split core or fixed core models The ACS200 series current operated switches are UL cUL and CE approved and prices start at 68 The ACSX series high performance current operated switch has a field adjustable time delay feature to minimize trips from high inrush or short overload conditions during start up and operation These switches are designed for motor status applications where setpoint accuracy and repeatability are critical The adjustable start up delay timer is field adjustable from 0 2 to 15 seconds The ACSX series is available in either normally open AC or AC DC outputs for use with most standard motor contr
6. matches but were beaten by the alliance that ultimately won that Regional The team was awarded the General Motors Industrial Design Award for the Palmetto Regional which celebrates form and function in an efficiently designed machine that effectively achieves the game challenge At the World Championships in April the Forsyth Alliance performed well winning three matches losing two and ending two in a tie They finished in the top half of their division and were recognized by a competing team with a peer Imagery award More importantly as viewed by the FIRST organization the Forsyth Alliance continued to encourage younger students to become involved in the program to foster their enthusiasm for science and engineering careers Among many community projects they spearheaded this season the Alliance mentored or financially sponsored over 20 new FIRST Lego League teams in schools in Forsyth County as well as hosted a local tournament for those teams to gain experience For more information photos and video of the Forsyth Alliance visit www forsythalliance com or for information on the FIRST program visit www usfirst org Eas 17 Technology Brief WAUTOMATIONDIRECT Semiconductor break throughs promise smaller faster chips By Chip McDaniel a bigger slower Chip AutomationDirect omputer chips are always getting smaller and faster right Historically this has been the trend
7. training forums weblogs and more AboutPLCs com also provides in depth information on AutomationDirect s DirectLOGIC PLCs Read Spotlight Feature Stories to learn interesting ways PLCs are used in industrial control Keep up to date with the latest news headlines in the world of manufacturing To see more visit www aboutplcs com Find answers at learn automationdirect com Learn automationdirect com is an online streaming tutorial site featuring video tutorials providing product information and training on a variety of industrial control topics Watch informative 1 to 30 minute segments covering product categories including PLCs operator interfaces software sensors motor control drives and 6 ee ee k OUTOTOTONOICECT Ce motors and more This new learning site is updated regularly adding more videos covering more products and general information about industrial control Each page of learn automationdirect com also has a link to our suggestions page where you can provide feedback and suggestions on information currently on the site You can also provide input regarding any tutorial video you would like to see added Be sure to check out http learn automationdirect com Make the site a bookmark in your Favorites section on your Internet browser We re sure you will return time and time again Allen Bradley DF1 protocols added to C more micro C more Micro Graphic operator interface panels now suppo
8. wont function and only switch ac or dc not both While some solid state packages are billed as having multiple poles those we have seen are individual SSRs with their inputs in parallel mounted in a single package One concern is what happens if just one side malfunctions That may be acceptable perhaps even desirable if the relay is controlling loads But it could be catastrophic in other situations separate When an EMR expires it s usually due to coil failure While contacts can weld if heavily overloaded this is a rare occurrence for a properly designed application and it is usually self evident EMRs can switch any ac or dc load up to their maximum rating Their contact resistance diminishes as the load increases eliminating any need for heatsinking Although EMRs require substantial coil power they operate at full load over a wide temperature range When the contacts are open there s nearly total line to load isolation that can only be bridged if the applied voltage exceeds the dielectric strength of the relay Most EMRs come with multiple poles and can control multiple voltages and circuits simultaneously Like all mechanical devices EMRs have finite life expectancies At some point best constructed and properly selected EMR designed even the www automationnotebook com will stop functioning In many cases though the equipment employing the relay wears out before the EMR With contacts
9. Awihomalion Direc has expanded ils range of producl lecusedd Webs siles bo incdude PLCs Check out www a beetles con Or visit any of our other learning amp support sites hip supperl sulomationdirecLcom Tang ew ae ae ee i E gt 7 toe a he ie bs Es 24 7 online store iftp wear aubomationdlrectcom Remote LL lato lai Fiat tee Fis breake bey te 7 WAUTOMATIONDIRECT Bhtmecaa i H ee E Pi eee ee ee eee eo a a TELET Automaton vote Look Symmer zoo ISSUE wre Technical Review Electromechanical Relays versus Solid State Each has its place By Tom Mahaffey Magnecraft amp Struthers Dunn Reprinted with permission from Penton Media Electronic Design Magazine ince the introduction of solid state relays some decades ago the debate over which is better solidstate relays SSRs or electromechanical relays EMRs has gone on The general answer is neither as each one has good and bad points But in terms of specific application requirements clear winners emerge When used as intended SSRs will perform indefinitely usually outlasting the equipment in which theyre installed They operate silently and produce little electrical interference SSRs will function over a wide range of input voltages and consume little power even at the high voltage limit They dont produce any arc making them suitable for hazardous environments M
10. CSA CE Ferraz Shawmut disconnects help you meet standards www automationdirect com circuit_protection Time delay and fast acting general purpose fuses SIRCO non fusible disconnect AutomationDirect ABB for control and electronic needs switches are available up to 800 Enclosures AY amp ratings starting at 57 Price Part Number Price Part Number Fusible di t e FUSERBLOC series of fusible 30A OE disconnects start at 85 break up to 200 amps with double break contacts per pole use with class CC or J fuses 115 00 2012 Fusible disconnect 449 00 2y 1 380 00 200A takes Class J fuses FBJ200 0S200J03 e Applications include service entrance and main panel disconnecting Non fusible disconnect 449 00 2y 1 420 00 se 400A rating V400 0T400U12 Non fusible disconnect 740 00 wy 2 200 00 Accessories include handles 600A rati g OeTL NFG0oASW and shafts terminal lugs and shrouds auxiliary contacts All prices are U S published prices AutomationDirect prices are as of April 2007 ABB prices are taken from ABB Publication LV023 No 1SXU 000 23 C0201 November 2005 Prices may vary by dealer Many other part numbers are available from vendors e Small dimension glass and ceramic fuses ideal for protecting PLC outputs pilot lights For more information or to order visit e Class M Midget fuses for supplemental bY Y a Se m www automationdirect com disconnects protection of transformers
11. S manufacturing remains strong and its better days believe it or not are yet to come Alive and well Last year the National Association of Manufacturers released a report on the state of U S manufacturing In contrast to the bleak picture often portrayed on TV and in newspapers The Facts About Modern Manufacturing reveals a dominant industry that s one of the primary contributors to America s success Manufacturing output in America is at an all time high playing a central role in our economy says John Engler president of the National Association of Manufacturers If it functioned on its own U S manufacturing would be the eighth largest economy in the world he adds All too often the perception is that American manufacturing s heyday is in the past but nothing could be further 8 from the truth says Jerry Jasinowski president of the Manufacturing Institute the research and education arm of the National Association of Manufacturers The facts show that manufacturing drives economic growth productivity and innovation in the U S and will continue to do so for years to come he adds Figure 1 If U S manufacturing was a country by itself it would be the eighth largest economy in the world ES e 2d oe Courtesy of National Association of Manufacturers Sources International Monetary Fund and Bureau of Economic Analysis 2005 One of the key observ
12. This trend was first observed by Intel co founder Gordon Moore in 1965 and the term Moore s Law was coined several years later For over forty years this law has held chips have gotten more complex and transistors have shrunk into the nanometer nm range z i e ir Aw g F T a i f sine i 4 ne Fa In 1965 Gordon Moore sketched out his prediction of the pace of silicon technology Decades later Moore s Law remains true driven largely by Intel s unparalleled silicon expertise Copyright 2005 Intel Corporation Today the traditional materials and production methods have been pushed to their limits Concerns about leakage current and overheating have caused many insiders to question whether the industry could continue its trend of doubling the number of transistors on a chip every two years They have warned 18 that Moores Law may soon have to be repealed Leakage current amp overheating Integrated circuits use insulating materials to isolate the gate of the transistor from the silicon substrate The gate is the electrode that when energized turns the transistor on and Researchers use the term high k to describe materials that have a dielectric constant or K value higher than 3 9k the dielectric constant of silicon dioxide Air is the reference point for dielectric constants and has a value of 1 These new materials are known to High k Metal Gate Tr
13. a GV2P14 All prices are U S list prices AutomationDirect prices are from April 2007 Price List Allen Bradley prices taken from http shop rockwellautomation com 02 13 07 Telemecanique prices taken from http www squared com 6 23 06 Siemens prices taken from http www sea siemens com 6 23 06 Sirius Contactors Catalog GE prices taken from online configuration tool at http www geindustrial com 6 26 06 Moeller prices taken from May 2003 Price Book at http www moellerusa net 6 23 06 ABB prices taken from http www abb control com 6 23 06 Price compar isons 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 not owned by AutomationDirect are the property of their respective manufacturers AutomationDirect disclaims any proprietary interest in the marks and names of others Prices subject to change without notice Allen Bradley Siemens 72 00 O 86 00 Y 3RT1016 1AK61 CLOOA310TJ 8 191 00 lt 200 00 3RT1035 1AK60 CL06A311MJ 159 84 150 00 125 00 140M C2E C10 3RV1021 1JA10 GPS1BHAK 78 00 A9 30 10 84 76 96 9 Amp Contactor 100 C09D10 a SC E02 110VAC 46 00 SC E2 110VAC 297 00 oe A40 30 10 84 J 192 00 MS325 12 5 40 Amp Contactor 10 Amp 46 Motor Starter BM3RHB 010 For more information visit www automationdirect com motorcontrols
14. a handful of manufacturers meeting the these requirements the highest criterion for requirements Among strict protection against attack by a vehicle is the ability to stop a 15 000 pound truck traveling at 50 mph within a 1 meter distance which is barely over 3 feet Intertex Barriers Inc of Valencia California is one of the manufacturers that have met these strict requirements The vehicle barricades in their unguarded position non deployed are below the surface Drivers typically are not aware stowed roadway of these protective devices as they pass over them Barrier types include raising bollards wedges and horizontal beams Powerful 2 500 PSI hydraulic cylinders are used to raise these large steel obstacles Deployment speed is adjustable and varies from 5 to 15 seconds for normal speed to less than 2 seconds during an emergency The barriers are not required to be operable after a vehicle collision but Automaton vote Look Symmer zoo Issy wre Barricades can be maintained in the deployed or non deployed state For high security installations or during periods of elevated threat levels barriers are always deployed and lowered only for passage of vehicle traffic after security clearance Multiple barricades in series make up a vehicle trap called vehicles individually a sally port for clearing Guards can selectively deploy a barrier in any traffic lane at normal d
15. called through silicon vias which are then injected with tungsten to create wires and electrical connections within the chip The breakthrough is believed to be production ready meaning that it would be useful beyond the lab and achievable in a production environment within the next year This breakthrough is a result of more than a decade of pioneering research at IBM said Lisa Su vice president Semiconductor Research and Development Center IBM This allows us to move 3 D chips from the lab to the fab across a range of applications The vertical connections will allow Continued p 25 gt gt www automationnotebook com FUN FACTS EXACTLY HOW SMALL IS 45 nm There are 1 billion nanometers nm in one meter e The original transistor built by Bell Labs in 1947 could be held in your hand while hundreds of Intel s new 45nm transistor can fit on the surface of a single red blood cell e If a house had shrunk at the same pace as the transistor you would not be able to see that house today without a microscope To see the 45nm transistor you need a very advanced microscope e The price of a transistor in one of Intel s forthcoming next genera tion processors codenamed Penryn will be about 1 millionth the average price of a transistor in 1968 If car prices had fallen at the same rate a new car today would cost about 1 cent e You could fit more than 2 000 45nm transisto
16. chip These will be sent to you free of charge Does the DL205 support an encoder input and drive a Question stepper motor simultaneously Answer There are two high speed counter modules available for the DL205 The D2 CTRINT which can only perform one of the functions either high speed pulse in or high speed pulse out and must occupy the slot next to the CPU slot 0 therefore only allowing one module per CPU system The D2 CTRIO which can handle both functions simultaneously allows for multiple modules used per CPU system dependent on power budget which can reside in any slot with the exception of slot 0 www automationnotebook com micro processors to be stacked on top of other chips such as memory chips Thus the connection distances between the chips can be reduced resulting in faster communications between the According to IBM the tech nique shortens the distance information chips needs to travel by 1000 times and will allow the addition of up to 100 times more channels or pathways for that information to flow compared to 2 D chips The new stacked chip configura tion is also touted to reduce heat dissipation and power usage IBM claims that the through silicon via can improve power efficiency up to 40 a huge benefit for battery operated devices such as cell phones and laptops The breakthrough will also allow advances for the multi core processors that have been proliferating
17. param eters such as retentive ranges DV 1000 setup parameters etc Question When using PID control with a D2 250 CPU the process variable values are incorrect What am I doing wrong Answer It s probably caused by a data format mismatch The Setpoint Value SP the Process Variable PV the Bias Integrator and the Control Output Value CO all use a binary for mat If using the pointer method in your ladder program for configuring the analog signals you can specify either BCD or Binary format If configured using BCD you must do a BIN conver sion before OUTing the value to Word 3 PV Also make sure that Word 5 CO is in the proper format For more information reference the loop table specifications located in the PID chapter of the User Manual What the Control Output on a PID control loop Question causes to not function Answer Most likely you haven t entered a high limit for your Control Output when configuring the PID setup The default value is 0 with a max imum of 4095 binary You must enter a value other than O in this field Word 31 using the PID setup or in your ladder program Check your Control Output word Word 5 to see if you are getting an output value If this value is changing and you still have no control output then verify that you are writing this value to the analog output card or the Time Proportioning ladder for discrete output control What the Setpoint Value in a PID loop to cha
18. the fuse is non replaceable so an external fuse is recommended Question My DL205 PLC won t recognize my I O module s What could be the problem Answer It s very possible that your firmware is too old When a new mod ule is introduced the PLC firmware must be updated to recognize the new module Question Where can I obtain the most current firmware for my CPU Answer All CPUs ship with the most current firmware If you have an existing CPU that needs to be updated to accept a new module or feature or improvement go to the following Firmware Page on our website to check of downloadable http support automa for availability firmware tiondirect com firmware index html or Technical Software Firmware go to Support gt Downloads gt Firmware You must download the Koyo Support Tool and the appropriate firmware binary for your CPU Unzip these files to extract the firmware binary and the Koyo Support Tool installation file Install the Koyo Support Tool as you would any other software program It will be listed as Firmware Update Tool under Start gt Programs Run the Firmware Update Tool It has a Wizard mode and a single page mode Most users will find the Wizard mode easier to use It will take you step by step through the process of updating the firmware in your CPU For CPUs that have their firmware on a PROM chip D2 230 and D2 240 you must call AutomationDirect Tech Support for a new firmware
19. to trouble free integration with the rest of the plant Two camps While software is the key difference between PACs and PLCs vendors vary in their approach to providing the advanced software Vendors start with their existing control software and work to add the functionality reliability and ease of use required to program PACs Generally this creates two camps of PAC software either software provided by vendors with a background creating PLC control or vendors with a back ground creating PC control Traditional PLC software vendors begin with a reliable and easy to use scanning architecture and work to add new functionality PLC software follows a general model of scanning inputs running control code updating outputs and functions A control engineer only performing housekeeping designs the control code because the input cycles output cycles and house keeping cycles are all hidden With much of the work done by the vendor this strict control architecture makes it easier and faster to create control systems The rigidity of these systems also negates the need for the control engineer to completely understand the low level operation of the PLC to create reliable programs the strength of the PLC architecture with rigid scanning architecture can also make it inflexible Most PLC vendors who create PAC software work to insert However Continued p 22 gt gt 21 Tech Thread cont Control Platforms
20. world s food and fuel needs from the same resources Other biomass resources include straw timber rice husks biodegradable waste and food leftovers Venture capitalist Vinod Khosla founder of SUN Microsystems and a major investor in both Brazilian biofuels and cellulosic ethanol says that the biofuels industry is poised for exponential growth and that biofuels made from cellulose appear to be the most promising alternative fuels over the long term Cellulose one of the most abundant organic materials on earth can be converted into liquid fuels either via a biochemical or a thermochemical conversion process The quality of timber or grassy biomass does not have a direct impact on its value as an energy source so waste products created in producing a commercial product can be used effectively for example rice husks from harvesting rice kernels sawdust from manufacturing lumber etc For more information on recent developments in biofuels visit www biofuelsjournal com for renew able energy sources in general the National Renewable Energy Laboratory www nrel gov covers biofuel wind fuel energy research solar cell and geothermal FIRST Robotics Team finishes exciting second season The Forsyth Alliance a team of high school students sponsored by AutomationDirect that participates in the FIRST For the Inspiration and Recognition of Science and Technology Robotics Competition accumulated more e
21. 2007 AutomationDirect Cumming GA USA All rights reserved FYI PLC Questions Answered WAUTOMATIONDIRECT DL205 Frequently Asked Questions ere are some of the more commonly asked questions pertaining to our DL205 family of PLCs For a more complete list go to the Technical Support page of our Web site Yes when DirectSOFT programming software connected to the CPU The D2 240 D2 250 1 and D2 260 CPUs all sup port bit override To enable bit override go to VIEW gt OPTIONS from the DirectSOFT menu bar Select the Data View tab and check Override Bits Next from the DirectSOFT menu bar select DEBUGsDATA VIEWSNEW OPEN Answer using es es o a g iP ta Ss Question Is the DL205 system expandable Answer PLC systems with a D2 250 1 or D2 260 CPU can be expand ed using the D2 EM Expansion module and D2 CM Expansion Controller modules Reference the DL205 User s Manual Chapter 4 Local Expansion I O section for complete details Another method of expansion is by using remote I O with a D2 240 D2 250 1 or D2 260 CPU The D2 240 requires the D2 RMSM Remote Master module A total of 896 I O points are configurable when using two Remote Master Modules with 7 slave units per module The D2 250 1 and D2 260 CPUs can use either the D2 RMSM module or the bottom port of the CPU A total of 2048 I O points are available when using up to 7 Remote Master Modules plus the CPU po
22. 475 675 F Does not include features requiring Ethernet audio CompactFlash CF P Full featured units http c more automationdirect com Order your free catalog or go online for complete specifications and pricing otf ONL iy thet value nautomation _ WA JTOMATIONDIRECT3 Copyright 2007 AutomationDirect Cumming GA USA All rights reserved TI 1 OUU 0O355 USU D
23. ansistors Metal Gate e Increases the gate field effect High k Dielectric e Increases the gate field effect e Allows use of thicker dielectric layer to reduce gate leakage HK MG Combined e Drive current increased gt 20 gt 20 higher performance e Or source drain leakage reduced gt 5x e Gate oxide leakage reduced gt 10x Silicon substrate HK MG Transistor Low resistance layer a a s High k gate oxide Hafnium based MeLal aale Different for NMOS and PMOS Diagram of Intel s 45nm High k metal gate transistor and its associated advantages in performance and leakage reduction Copyright 2005 Intel Corporation off Current that leaks past the insulation is not just wasted energy it results in unwanted heat Leakage current and the resulting heat generated have become more of a problem in recent years as transistor counts have continued to increase and decreasing transistor sizes have approached the atomic level The issue of leakage current increases exponentially as the number of transistors increases High k metal gate materials Intel Corporation has developed several new insulation materials for use in transistors which make up computer chips These new materials replace the silicon dioxide dielectric material which has been used for over 40 years include various alloys of Hafnium but the actual metals used are a trade secret The high k dielectric
24. arings and shaft She had never seen any products returned before that had been stripped of all the internal parts It was then that I suddenly realized that I had sold all of our tradeshow servo products to my friend in Asia dummy products that to keep the weight down for transport to and from tradeshows looked good but didn t func tion I ll never know if anyone ever believed it was a complete oversight on my part and not a plan to deal with a very persistent salesman EET Brainteasers Think Inside the Box Can you assemble these 8 pieces into a 6 x 6 square Home Alone A homeowner went to the hard ware store to purchase a common household item She found that she could buy 1 for 0 50 12 for 1 00 and 144 for 1 50 What was she buying Think Inside the Box II Can you cut the figure below into four pieces that will fit together to form a square Think Inside the Box III Can you cut this E into 5 pieces that will form a perfect square Each colored section is a square and all are identical in size You may rearrange and rotate only no flipping Extra credit Can you do it with only 4 pieces if you are allowed to flip any of the pieces 1 Build your panel for peanuts TRAIAN ds Full line of Hubbell Wiegmann enclosures protect your systems e Over 1 500 part numbers in wall mount floor mount and freestanding units e NEMA 1 3R 3S 4 4X 6P 12 and 4 12 ratings
25. ations made in the report is that manufacturing influences the U S Gross Domestic Product more than any other market segment Its contribution to real growth since 2001 ranks highest among all sectors at 15 percent In 2005 alone manufacturing contributed 1 5 trillion to the GDP and it continues to grow faster than the economy overall This upward trend according to the report owes largely to improvements in productivity Over the past decade manufacturing productivity more than doubled Today more goods are made in America than any time in U S history The casual observer may equate produc tivity to widgets per minute but in the big picture its measured in wages and benefit compensation In fact produc tivity growth is perhaps the single most important determinant of average living standards says Ben Bernanke Federal Reserve Chairman Another relevant fact in the report is that manufactured goods account for more than 60 percent of the products America exports helping offset the cost of what we buy from abroad What agricultural exporters bring in each year about 50 billion manufacturers take in each month This is especially weighty in light of the claim by former Federal Reserve Chairman Alan Greenspan that the three sources of original wealth are agriculture manufac turing and mining Besides its role in producing new wealth manufacturing has a huge multiplier effect on the economy Each manufac
26. ave started around 1974 In Japan France Canada and the United Kingdom tort costs are less than one percent of the GDP in the U S they re more than double amounting to 250 billion a year much of it sucked from the manufacturing sector Another challenge cited by the report involves government regulations In 2005 the regulatory load on U S manufacturers was 162 billion 32 percent higher than that imposed on manufacturers by our nine biggest trading partners Manufacturers also face higher taxes in the U S The corporate tax rate here is about 40 percent compared to 28 percent and falling in developed nations with which we compete a eel pan my Rising health care costs are yet another concern Drivea by escalating malpractice claims and insurance premiums health care now consumes up to a third of the revenues manufacturers bring in Were it not for these structural non wage cost disadvantages health care taxes liability and regulatory expenses manufacturing in the U S would be more economical than in Germany France Canada and the U K and roughly on par with South Korea Perhaps the most complex Figure 3 The U S education system is not producing enough engineers and skilled workers for tomorrow s more technologically complex world Derr LiF ipa rra d eee r Courtesy of National Association of Manufacturers Source U S Dept of Education www automationnotebook
27. cal columns tutorials and articles to our readers Recently I have been asked about frequency of the issue and our mailing schedule Although we strive to produce this publication consistently we may vary between two and three issues per year depending upon product launch and catalog schedules We strive to be efficient with our mailing process to keep you informed with timely information Having been part of the AutomationDirect team since 1996 I am elated to be part of this growing company dedicated to supporting this industry and you our customers I ve had the pleasure of meeting top editors and have a deep appreciation for their insight in this constantly evolving field of technology One such editor is Larry Berardinis we are especially honored to have Larry as our guest writer with a special focus on the U S manufacturing sector Innovative technology has altered the way many businesses operate today While concerns of outsourcing abound U S manufacturers are working toward increased efficiencies as a key competitive driver as they strive to keep manufacturing here and overall I think you will see the results are more promising than we realize I hope you will continue to send your comments and suggestions to us we hope you enjoy this issue of Automation Notebook a lipe Tina Crowe Publisher editor automationnotebook com www automationnotebook com Table of Contents New Product Focus 4 Automa
28. ciated with stolen IP add up quickly and are rarely recovered Getting stronger From its golden past to the rock solid foundation it operates on today U S Continued p 10 gt gt 9 Cover Story cont VAUTOMATIONDIRECT The Stare of NS Hanntacturing manufacturing is on a course that not only will rise to meet the latest challenges but also scale new heights as manufacturers evolve to meet the needs of our rapidly changing world here as well as abroad An example of the sorts of changes we re likely to see can be found along the path of the U S bicycle industry During the height of its success Schwinn was one the top bike makers in America In its main Chicago plant it manufactured rims and frames onto which it assembled gears brakes pedals hubs and other parts that it imported from as many as eight countries In addition to being a smart manufacturer Schwinn was an intelligent marketer able to anticipate if not influence consumer trends and then develop products that met the demand Figure 5 U S exports to China would have doubled had trade rates between the countries remained what they were in 1998 i ia pi Hj bia pi Jr m Courtesy of National Association of Manufacturers Source NAM calculations based on China Customs data through Global Trade Information Services and the U S Dept of Commerce WTO entry 12 2001 Schwinn eventually succumbed to the strain o
29. com challenge facing American manufac turers is that of exchange rates The stronger the dollar relative to a trading partner s currency the more difficult it is to command a fair price for goods Exchange rates the report claims triggered the manufacturing recession of 2001 Unfavorable rates caused exports to drop from 771 billion in 2000 to 681 billion in 2002 When exchange rates were realigned in 2004 U S exports soared to over 900 billion the following year Figure 4 Tort costs in the United States are out of control increasing several times faster than the Gross Domestic Product Trial lawyers who pocket over 40 billion annually from lawsuits seek big targets often leading them to manufacturers m o aa ce a a a Courtesy of National Association of Manufacturers Source Bureau of Economic Analysis and Towers Perrin Establishing fair rates with China is especially difficult China artificially pegs its currency to the value of the U S dollar Worse since 1998 it has continually reduced the percentage of U S goods it imports Because of this growing imbalance the U S is no longer the largest exporter in the world That distinction now belongs to Germany not surprising given that China imports 50 percent more goods from the European Union than the LS Another disadvantage U S manufacturers have when trading with China is their inability to enforce intellectual property laws Losses asso
30. curity control room are used to display status and control the barriers www automationnotebook com Expansion slots for additional modules allow for flexible input and output configurations AutomationDirect s Hubbell Wiegmann NEMA 4 electrical enclosures protect the electronics The enclosures house the PLCs power supplies motor starters circuit breakers fuses terminal blocks sensor electronics and accessory relays If Continued p 14 gt gt 13 Feature Story cont PLCs tn ACTION WAUTOMATIONDIRECT required connectivity to provide remote operation and to report system status to higher level security systems is accomplished using PLC PC hardware with either DeviceNet DO DEVNETS or Ethernet HO ECOM communication modules To help lower production costs and remain price competitive AutomationDirect products are used throughout the The support and from AutomationDirect has made a big systems response difference in the ability to service customers requirements in a timely manner As a effective vendor AutomationDirect is one of Intertex Barriers top suppliers Necessary with each barrier type the horizontal beams render vehicles totally inoperable The wedge barrier in a fully deployed position 14 Enclosure containing DLOG PLC Rhino power supply and Cutler Hammer motor controls Helpful learning and support sites from AutomationDirect
31. e Metal and non metal lines e JIC boxes pushbutton and operator consoles www automationdirect com enclosures Screw type terminal blocks for point to point wiring ii oe a e In standard gray plus seven colors for popular sizes e Ground disconnect and fluse blocks available e Mini terminal blocks for space limited applications e Multi level blocks for 3 wire device wiring e Screwless terminal blocks also available www automationdirect com dinnectors RHINO DC switching power supplies with 3 year warranty as low as 55 50 U S e PSM metal series in 12 and 24 VDC adjustable output models from 78 to 600W e PSP plastic housed ultracompact series in 5 12 and 24 VDC models up to 8A output current www automationdirect com power You demand top quality pilot devices at great prices so we offer a range of styles and sizes to meet your needs and your budget Choose from the HT800 30 mm metal NEMA series 22 mm metal or non metal stacklights for panel controls e Flush extended illuminated or non illuminated mushroom and guarded pushbuttons many available in multiple colors e Pilot and push to test lights green operator 1 e Selector switches in knob lever and keyed versions 3 unit preassemb steady incandesc green amber red e Stacklights in modular or pre assembled units AutomationDirect prices a 2005 All prices are U S lis Pushbuttons Stacklights black opera
32. elect from one of the optional keypad bezels available in a numeric with control buttons keypad or a simple control button keypad And they re plug and play no software configuration required For a full tour of the hardware and software Way visit RBYP T Siik D O y Ain ue i E Meal onveR ONL Ne i m ML hes ei ih Copyright 2007 AutomationDirect Cumming GA USA All rights reserved WAUTOMATIONDIRECT a J J ONC L Cover Story The Stave of U8 Hanutacruring WAUTOMATIONDIRECT Made in America Opinions abound but the facts show U S manufacturing to be a global powerhouse evolving to meet tomorrow s changing needs by Larry Berardinis Editor Motion Systems Design ince the early American settlers began making their own goods in their new homeland U S manufacturing has been an engine of incredible wealth In simply meeting the essential needs of life providing food clothing shelter and safety it has created a standard of living that benefits hundreds of millions of people not just domestically but also abroad Where riches are plentiful however so too are thieves From the shop floor to the boardroom from Wall Street to Capitol Hill in courtrooms and in union halls innumerable profiteers have glommed on to American industry putting enormous pressure on the system keeping us and them alive The good news is that despite the strain U
33. ent was no There was one sales manager from an Asian country Taiwan that was very persistent and creative concerning the servo products He finally got permis sion for us to display our products in his booth at a local tradeshow with the agreement that they could not sell anything but just gauge the interest from customers I was asked to attend the show to answer any questions that about the products Interest was intense and when customers might have it came time to pack up the products I was asked by the sales manager if he could just purchase the show products for resale to select customers After much discussion back and forth I finally agreed deciding I would just have to handle any political issues after returning to the home office As expected many management discussions ensued with the final outcome being to allow our products 26 into this one country with certain commercial guidelines Mission accom plished and I m on to new frontiers or so I thought Several weeks later the manager of our repair department came to my office to review a very strange situation A large number of our servo products were being returned by the Asian branch of our parent company with the complaint simply being that the products wouldnt run The strange part that our manager wanted to review with me was that none of the motors had any laminations windings magnets encoders or any other internal parts just housing be
34. eployment speed When a serious threat is perceived operating an emergency fast response mushroom style pushbutton raises all barriers at full speed Other deployment methods include vehicle more autonomous speed sensing radar roadway detection loops and wrong way detection sensors Inadvertent operation is avoided by vehicle presence detection using FG series through beam photoelectric sensors offered by AutomationDirect over barrier surfaces and or via detection loops buried in the pavement immediately before and after the barriers The control system monitors barrier position using AutomationDirect s AT series inductive proximity switches Barrier proximity switch status is used in the PLC pro gram to report barrier positions display indication on the operator panels and to control other devices such as traffic signal lights electric gate arms warning horns annunciators and strobe lamps energy also allows barrier operation during complete loss of facility electrical power Battery backed power supplies can keep the control system active for several hours without main power All hydraulic power unit functions are controlled by AutomationDirect s DirectLOGIC programmable logic controllers PLCs Inputs from the operator panels initiate operation of the hydraulic solenoid valves Cutler Hammer motor controls operate the electric motors driving the hydraulic pumps Using information from fluid pres
35. f the many challenges manufacturers face but in its place several new U S bicycle makers emerged following a fairly similar formula Targeting high margin niches companies such as Cannondale Haro Specialized and Trek have come of age employing high value manufacturing processes that turn out customized frames in a variety of styles and sizes What happened in the bicycle industry reminiscent of a cell dividing into multiple units is about to be repeated in many industries in many ways catalyzed by advances in automation technology Even in the auto industry we may see new U S manufacturers and perhaps old ones 10 reborn all moving more quickly and effectively with the help of programmable automation In a nutshell programmable automation is the means by which manufacturers are achieving software retoolable factories It is likely to bring about a renaissance in manufacturing in large part because it is scalable With reduced entry costs teams of talented people will more easily form to serve high value high margin manufacturing niches whether it s cars clothing health and wellness household appliances or food Besides encouraging startups programmable automation also upgrades the roles of everyone in industry Not long ago equipment operators spent the majority of their time turning cranks and dials and loading machines Today factory workers run machines primarily through computers spendi
36. fuses FUSERBLOC switches provide reliable circuit protection For more information go to www automationdirect com disconnects MHH EET Get premium features at best value prices The C more Micro is a graphical operator interface panel at a text panel price Choose either the touch or non touch version depending on your application and budget Either way you get advanced features at prices you might typically be paying for more limited text panels e Five backlight colors that can alert operators to conditions by changing or flashing the color of the screen Five dual purpose configurable function keys with individual LEDs e Recipes e Alarms e Up to 999 screens dependent on screen complexity e Protocols supported All AutomationDirect PLCs Screen Colt Modbus RTU i Allen Bradley DF1 half full duplex PLC5 DF1 Combine these features and more with the free downloadable programming software and you have a panel that s flexible cost effective and is perfect for a wide array of applications The programming software is free when downloaded from the Automationdirect Web site or the CD ROM package can be purchased for 25 part EA MG PGMSW Data Entry and Control SPECIFICATIONS w 21 dynamic or 32 static UL cUL CE RoHS NEMA 4 4X indoor use res FREE download or 25 for CD 999 Screens Max limited by memory For additional data entry and control s
37. ger Justin Stegall Contributing Writers Larry Berardinis Jeff Anderson Chip McDaniel Joan Welty E E CONTACTS Automationdirect com Inc 3505 Hutchinson Road Cumming GA 30040 Phone 1 800 633 0405 or 1 770 889 2858 Fax 1 770 889 7876 Monday Friday 9 a m to 6 00 p m EST www automationdirect com Copyright 2007 Automationdirect com Incorporated All Rights Reserved No part of this publication shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated Automationdirect retains the exclusive rights to all information included in this document If you are a non subscriber and would like to be included in the next mailing of AutomationNotebook please visit http www automationnotebook com freestuff html on the Automation Notebook Web site and complete the details You can also request FREE stuff including our catalog and our CD ROM featuring the entire catalog and demo software If you provide your email address we will send news and product information from time to time as well For those who prefer to speak with us in person please call 1 800 633 0405 x1845 Thanks for your interest and we look forward to hearing from you Publishers Note The inaugural issue of Automation Notebook mailed three short years ago in June of 2004 At that time we had outgrown our newsletter and wanted to offer more techni
38. gged environments The PC suffered from three main problems Stability Often the PC s general purpose operating system was not stable enough for control PC controlled installations were forced to handle sys tem crashes and unplanned rebooting Reliability With rotating magnetic hard drives and non industrially hard ened components such as power sup plies PCs were more prone to failure Unfamiliar programming environ ment Plant operators needed the capa bility to override a system for mainte nance or troubleshooting Using ladder logic they knew how to manually force a coil and patch code to quickly override a system But with PC systems opera tors needed to learn new tools Although some engineers use spe cial industrial computers with hardened hardware and special operating systems most engineers avoided PCs for control because of problems with PC reliability In addition the devices used within a PC for different automation tasks such as I O communications or motion may have different development envi ronments So the 20 percenters either lived without functionality not easily accom plished with a PLC or cobbled together a system that included a PLC for the control portion of the code and a PC for the more advanced functionality This is the reason many factory floors today have PLCs used in conjunction with PCs for data logging connecting to bar code scanners inserting information into databa
39. ica tion and maintenance By the mid 1970s manufacturing experts replaced relay based control with PLCs These early controllers com monly used bit slice based CPUs such as the AMD 2901 and were limited to digital control For reliability and ease of programming PLCs employed rigid control architectures and simple instruc tion sets Engineers programmed the majority of them using ladder logic a language created to mimic the original relay diagrams 80 20 rule During the three decades PLCs evolved to incorporate following analog I O communication over net works and new programming standards such as IEC 61131 3 However engi neers create 80 of industrial applica tions with digital I O a few analog I O points and simple programming tech niques Industry experts estimate that 80 of PLCs are used in small applications less than 128 I O 78 of PLC 1 0 is digital 80 of PLC application challenges are solved with a set of 20 ladder logic instructions Since a user can solve 80 of industrial applications with traditional tools there is strong demand for simple low cost PLCs In fact some PLCs still use the original AMD 2901 CPU and some companies only offer ladder logic programming for their PLCs This sta bility gives engineers the benefit of long life cycles on their control hardware and gradual changes to programming soft ware making it easier to train techni cians and perform main
40. ing s GDP is spread across nine industries which includes both durable and nondurable sectors naa Cm he es La karte gre BF ger Er E Dij F FE a T E pe inja LE ij u ee ee j LE aa EE parea ED FE 2 Hy osilar ee Courtesy of National Association of Manufacturers Source NAM calculations based on U S Dept of Commerce data 2004 now spends two percent of the GDP on tort claims making the loss of R amp D support even worse Another challenge facing manufac turers is a growing manpower shortage In a recent survey conducted by the Manufacturing Institute over 80 percent of manufacturers said they could not find qualified workers to fill open posi tions Compounding the problem our colleges are producing fewer engineers and our high schools are graduating fewer seniors with the skills necessary for today s more technical jobs According to the report in 2000 23 percent of all undergraduate degrees awarded globally were in natural science or engineering The U S was far below the average at 11 percent while China at 50 percent was far above Perhaps one reason fewer people are going into engineering is that our runaway tort system makes it much easier to take wealth than create it Rising tort costs are in fact one of manufacturing s biggest concerns Although the U S economy is growing at a healthy clip tort costs are increasing many times faster a trend that seems to h
41. is one of many steps that have been pioneered to help alleviate heat problems and promise to reduce leakage current 100 fold The use of high k material has also required that a material be found for the transistor s electrode This new electrode is referred to as a metal gate and it replaces the new compatible polysilicon gate electrode material that has also been used for many years The working combination of the high k dielectric and the metal gate is perhaps the most important breakthrough in transistor design in forty years Implementation of high k and metal materials marks the biggest change Automaton vote Look SNMMEL 2007 ISSE Mine in transistor technology since introduction of the polysilicon gate MOS transistors in the late 1960s says Gordon Moore i a i a m F a i ae ya er tae ii hk i a Gordon E Moore Co founder Intel Corporation Copyright 2005 Intel Corporation Intel is confident that the new technology will allow transistors to continue to shrink and allow the industry to continue the 2 year cycle of Moores law for several additional generations of microprocessors The first application of the technology will be in a 45nm transistor For reference a nanometer is one billionth of a meter See the sidebar for some interesting facts about just how small a 45nm transistor is Just ten years ago a state of the art transistor was 250
42. l l i Increased tub DE opening for better access The NEMA 4 12 series featured here is designed to house and protect your valuable electrical components from harsh dirty environments Check out the advantages of this rugged and durable design GIAN and then check out the great prices t NON METAL s bap Ly AutomationDirect TKS Hoffman i i p i Enclosures Price Part Number 2332 Price Part Number 16 0 Q Q All prices are U S published prices AutomationDirect prices are as of April 18 2007 Hoffman prices are taken from Hoffman price list dated 01 15 07 Prices may vary by dealer Many other part numbers are available from vendors NEMA 4 12 ULTIMATE Also Available wall mount 36 x 24 x 8 l e Over 1 500 part numbers i bi j NEMA 1 3R 4 4X 12 and 4 12 r w i e Metal and Non Metal NEMA 12 wall mount 16 x 12 x 8 147 50 N12161208 138 50 N10242408LP 342 70 A 161208LP 309 90 A 24N24BLP 397 60 A 201608LP NEMA 1 wall mount 24 x 24 x 8 Call to request your free catalog or place orders or go online for complete technical details full pricing and convenient ordering NEMA 12 wall mount 20 x 16 x 8 186 50 N12201608 For more information visit www automationdirect com enclosures WAUTOMATIONDIRECT www automationdirect com 1 800 633 0405 the 1 value in automation Copyright
43. lately These dual core and quad core devices are limited by their current vertical only implementations and the 3 D technology can put power closer to each core increasing the speed of the and consumption by 20 according to IBM It may also be pivotal in the processor reducing power development of larger scale multi core processors with 8 16 or more cores For more information Intel s Technology and Research page http www intel com technology IBM s press release on the 3 D technology http www 03 ibm com press us en pressrelease 21350 wss Moore s Law http www intel com technology mooreslaw index htm http en wikipedia org wiki Moore s_ law e 25 The Break Room WAUTOMATIONDIRECT Yymorous S7Ories and Brainteasers Ta Best in Show from an AutomationDirect employee referring to an experience at a previous company he business I worked for some time ago was acquired by a large multi national company and we were initially maintained as an independent subsidiary including our own sales channel We were requested to maintain the separation from the parent company especially with regards to their sales channel However we had some very interesting brushless servo products that the parent company did not have and there was widespread interest from the parent s sales force to have access to our products However as explained before the answer for the pres
44. lications collect high speed measurements for vibration or power quality applications This data allows the user to monitor the condition of rotating machinery determine maintenance schedules identify motor wear and adjust control algorithms The data is specialized data acquisition systems or normally collected using standalone instrumentation and is incorporated into a control system using Some PACs today can directly take high accuracy a communication bus measurements at hundreds of thousands 22 or millions of samples per second allowing engineers to pull data directly into their control systems Engineers also can incorporate vision into their control systems Vision is an area of automation that has gained a lot of momentum in the last decade In a manufacturing environment there are many flaws or mistakes you can catch through visual inspection that are difficult to detect using traditional measurement techniques Common applications include part inspection for manufacturing or assembly verification such as checking for correct component placement on a circuit board optical character recognition to examine date codes or to sort products and optical measurements to find flaws in products or for sorting by quality Many plants currently use standalone smart cameras that need to communicate to the manufacturing process controller PACs that incorporate vision or high speed measurements with logic and motion co
45. ll function digital timers for 91 50 www automationdirect com relays a a i dh u a p i l f F A f r4 o l a i o P A 7 A k F H M b os of a 4 7 i i ae aS Your HMI choice is now even easier Choose reliability ease of use and premium features all at prices you won t get from the traditional automation suppliers C more touch panels are backed by a two year warranty and our 1 rated technical service as voted by readers of Control Design magazine in multiple product categories for the last six years es ge C more touch panels offer a Analog resistive touch screen so Full featured units include built in there are no defined touch cells to Ethernet port with drivers C mo re touch pa nel limit screen design see Web for complete list prices h ave dropped e TFT displays offer 65K colors e Serial protocols supported f 1 2 Symbol Factory 4 000 symbol library All AutomationDirect PLCs an average O Oo Popups overlapping objects e Modbus RTU some units as much bitmap animation Allen Bradley DF1 half full ac 90 1 Alarms fill in the blank event duplex PLC5 DF1 as manager e GE 90 30 SNPX Omron Hostlink USB Compact Flash ports for data others logging e Configuration software only 129 ee C more touch panel line up CHECK OM NEWTONS ICES m 7 395 595 775
46. more investments in manufacturing in the U S accelerating growth that much more Some mistakenly believe manufacturing in the U S is in decline says Dennis Cuneo senior vice president of Toyota Motor North America one of the sponsors of the National Association of Manufacturers report On the contrary U S manufacturing is vibrant and robust Cuneo says In fact we believe the United States will remain the biggest and most successful competitor in global manufacturing and we intend to help it do so by continuing to expand our investment in American manufacturing And Toyota to be sure will not be alone To get a copy of The Facts About Modern Manufacturing published by the National Association of Manufacturers log on to www nam org facts m Larry Berardinis Bio Larry Berardinis is Chief Editor of Motion System Design prior to which he was Managing Editor for Machine Design covering electronics and motion technology He also worked as an engineer at Cincinnati Electronics Corp developing optical sensors and automated measurement systems and as an intern at NASA Glenn Research A member of Eta Kappa Nu he has a Masters of Science in Solid State Electronics from the University of Cincinnati and a BSEE with a physics minor from Cleveland State University at Lt De a ae a ee pen Se Fe FS F4 FS Motion Control Copyright 2007 AutomationDirect C
47. mstances Tom Mahaffey has been studying relays and their applications since joining Struthers Dunn now Magnecraft amp Struthers Dunn in 1979 kat 15 Fuji Electric Qua at AutomationDirect prices SA Motor Sta re SS o DUO and Odyssey series motor controls up to 300 hp Get Fuji Electric s best motor control solutions from AutomationDirect With sizes up to 300 hp at 480 VAC this complete series of IEC contactors overload relays and manual starters offer you any motor control configuration you might need Both the DUO and Odyssey line are available in 24 VAC 24 VDC 120 VAC and 240 VAC coil versions Contactors are available with e Three compact frame sizes up to 300 hp 24 VDC 24 VAC 120 VAC and 240 VAC coils e Larger models use a SUPER MAGNET for high operating reliability Finger protection terminals Manual Motor Starters feature e UL 508E listed Type E and Type F group motor rated e Two frame sizes up to 63 amps Up to 50 kA short circuit current rating SCCR at 480 VAC e Thermal and magnetic protection e Manual ON OFF control with lockout capability Add a contactor link module and base plate to create a combination starter Moeller 5102 00 29 0 g 136 00 PKZMO0 6 3 SP AutomationDirect TKS Telemecanique Motor Controls Fuji wy 34 00 LC1D09 wy 218 00 171 LC1D40 100 C37D00 This product includes 1 N 0 Aux contact 155 00
48. ng much of their time fiddling with the virtual equivalents of yesterdays cranks and knobs Tomorrow however is a whole new ballgame Operators working in intelligent automation environments will no longer be buttonpushers because machines will run themselves People meanwhile will function at a higher level interacting with the process rather than the equipment This will allow operators to spend more time improving quality throughput and yield Of the many indicators pointing to the coming revolution in industrial automation the most convincing is upward programmability The age of intelligent programmable components is here and it is giving rise to a new era of intelligent machines and processes on which programmable automation is based Programmable automation is hierarchical and now made possible by intelligent machine components that can gather process store and share information across industrial computer networks The U S is especially well positioned to excel in this area because a large portion of industrial R amp D is dedicated to computer hardware and software Nearly 30 percent of America s industrial R amp D budget goes to computer technology compared to the 15 percent allocated by other countries This broader distribution of industrial R amp D in the U S will also pay dividends by expanding our knowledge in the many domains where automation is applied All this is likely to stimulate even
49. nge Question causes e s E R ED e s a e 5 e es Automaton vote Look Symmer zoo7 Issy Mine Technology Brief Continued when switching from Manual to Auto mode using PID View or ladder Answer You are probably in Bumpless Transfer Mode 1 In this mode the Setpoint Value is forced to the Process Value on a manual to auto transition You should use Bumpless Transfer Mode 2 if you do not want this This is Bumpless Transfer section of the PID to occur covered in the chapter in your User Manual Question Can the DL205 be used in a Modbus network Answer Yes if Modbus RTU hex is the supported protocol the D2 240 D2 250 1 and D2 260 CPUs can all be used in a Modbus network The bottom ports of the D2 250 1 and D2 260 can be configured as a Modbus master or slave The D2 240 bottom port sup ports slave mode only Also our Data Communications Module DCM can respond as a Modbus slave when used with the D2 240 D2 250 1 or D2 260 CPU The D2 230 cannot be used on a Modbus network Question Does the support Profibus protocol Answer Yes using the H2 PBC Profibus Slave Base Controller This unit operates as a slave only and replaces the CPU in the DL205 rack For more detail view the H2 PBC M manual in the documentation section of our Web DL205 site Question Does the DL205 base power supply have an internal fuse Answer Yes it contains a 2A 250V slow blow fuse However
50. nm 5 5x the size and 30x the area of a 45nm device Further good news from Intel indicates that the technology can be produced using techniques similar to the techniques in use today at their existing fabs new transistor semiconductor manufacturers refer to their factories as fabs and without having to completely re engineer the fabrication process Production parts are expected to ship in 2007 and actual CPUs could be available in early 2008 Intel announced in mid January that the first 45nm architecture Penryn has been successfully tested with several operating systems including Windows Vista Windows XP MacOS X and Linux Penryn will form the basis of several CPUs with code names like Wolfdale Yorkfield and Montevinia The dual core Penryn processors will contain 410 million transistors while the quad core versions will contain over 800 million Die photo of an Intel 45 nm shuttle test chip including 153 Mbit SRAM and logic test circuits Copyright 2006 Intel Corporation 3 D Chips Another technical breakthrough has been announced by IBM To date all connections to computer chips are made around the perimeter of the chip It s common knowledge that many semiconductor companies have been working on methods of connecting chips in a vertical manner IBM has been working on the concept for more than 10 years IBM s new method allows holes to be etched all the way through the chip
51. ntrol eliminate the need for engineers to integrate dissimilar hardware and software platforms You can see the future of PACs by looking at the latest PC and embedded software One example is the ability to use software to define hardware Field programmable gate arrays FPGAs are electronic components commonly used by electronics manufacturers to create custom chips allowing intelligence to go in new devices These devices consist of configurable logic blocks that can perform a variety of functions programmable interconnects that act as switches to connect the function blocks together and I O blocks that pass data into and out of the chip By defining the functionality of the configurable logic blocks and the way they connect to each other and to the I O electronics designers can create custom chips without the expense of producing a custom application specific integrated circuit FPGAs are like having a computer that rewires its internal circuitry to run your application Normally FPGA technology has only been available to hardware designers who were proficient in low like controls level programming languages VHDL however engineers can use high level graphical today development tools to create custom control algorithms that download onto FPGA chips This advancement enables engineers to incorporate extremely time critical functions to hardware such as limit and proximity sensor detection and sensor health m
52. ol systems The switch serves as an electronic proof of operation by detecting current draw changes in motors when they encounter problems such as pumps running dry or pending breaking failure The ACSX series switch also provides much quicker response time than Class 10 overload relays The ACSX series switches are UL and cUL listed and CE approval is pending Prices start at 79 The complete AcuAMP series of transducers and switches can utilize a DIN rail adapter priced at 3 50 for a pack of two Ferraz Shawmut quality at AutomationDirect prices Vibuns Molded Case Circuit Breakers for branch and feeder circuit protection starting at 157 U S M za a ay j X i aN y Made by Eaton Electrical Inc Manufacturer of Cutler Hammer products e G F K and L frame sizes from 15 to 600 amps e High speed blow open action e Small size saves panel space UL489 listing Get unmatched circuit protection with 600 VAC 250 and IEC rated A wide array of handles is VDC heavy duty fusible and non fusible disconnects available for OSHA padlocking requirements NEMA from Ferraz Shawmut Meeting UL98 standards the configurations defeater options and NFPA 79 SIRCO and FUSERBLOC series are designed with the requirements Check the chart for just a few examples latest disconnect technology available make and of the components we carry break power circuits under load and are UL
53. onitoring Because the control code runs directly in silicon it is possible for engineers to quickly create applications that incorporate custom communication protocols or high speed control loops up to 1 MHz digital control loops and 200 kHz analog control loops PLC vs PC vs PAC The industrial tools that push the boundaries 20 percenters seeking of controller technology are quickly adopting programmable automation controllers As PAC software evolves to provide more flexibility and ease of use these products will become common in industrial measurement and control applications The potential of easier programming for real time operating systems FPGAs and digital signal processors also is making machine and skid builders take notice However with 80 of applications needing relatively simple control and computers available for a few hundred dollars PCs and PLCs maintain a bright a future in industrial control It is evident that PACs do not settle the dispute about the best control platform but instead add another dimension to the debate NEMA Enclosures Our prices can save you 50 ait Larger sub panels Poured in Place Easily Removable nS to accommodate polyurethane gasket st bigger footprints fe N412C ULTIMA NEMAR ZSeries Certified UL 508 Listed Meets NEMA Type 4 Ve amp 13 h y N Bodies and doors fabricated from 14 gauge stee
54. ost ac switching types employ zero voltage crossover which minimizes surge currents SSRs have no moving parts so physical shock vibration or changes in altitude won t affect them SSRs aren t relays at all but rather electronic circuits Typically an SSRs input consists of an opto isolator while its output is a triac SCR or FET One negative aspect of an SSR is that semiconductors are never completely on or off In the on state substantial resistance is present which can lead to significant heat generation when current is flowing So SSRs must be mounted on heatsinks often several times the relay s weight Theyre sensitive to ambient heat and must be derated if used in hot environments or with less than optimal heatsinks In some applications on state voltage drop can cause problems for loads that are sensitive to reduced voltage When off the resistance goes up but the circuit path isnt completely Off state enough current flow at higher voltages open resistance permits to be objectionable even dangerous Under normal service conditions SSRs seldom fail But when they do they nearly always fail shorted The user might not realize that the relay has failed depending on the load being controlled or no longer being controlled When exposed to surges or spike voltages on the controlled line SSRs may conduct for as much as one half cycle after the surge has stopped Most require a minimum load or they
55. pt target positions from the PLC via the serial Modbus connection The servo drive can then determine the required motion profile internally and move the motor to the target position SureServo also supports analog and pulse inputs if you would rather use an analog PLC output or a high speed pulse output to control your motion Want even simpler motion The built in indexer can store up to 8 predefined moves Simply use discrete outputs from the PLC to trigger those moves SureServo systems come in eight standard sizes from 100W to 3kW of continuous output power Prices for a complete system including drive motor connection cables and interface kit start at 965 00 U S SVA 2040 SVL 201 SVC PFL 010 SVC EFL 010 ASD BM 50A plus free downloadable set up software please visit www sureservo com IRECT ALITAIMATINNOAWACT COM I gt Te aTr A L AULOMAaUONQITeECL CO l Li I OW JIITVI TU Feature Story PLCs rn ACTION WAUTOMATIONDIRECT Anti terrorist Barriers Help Protect Facilities By Jeff Anderson Intertex Barriers Inc A Division of Boon Edam Tomsed ince the terrorist attacks of September 11 2001 the need for perimeter security of potentially threatened facilities has increased dramatically To accomplish this several facilities around the globe International installations include US Embassies and consulates The US Department of State sets strict standards for these barriers with only
56. rds in fully guarded position consist of a series of large retractable steel obstacles have been installing devices called anti terrorist barriers used as added protection against invasion of potentially dangerous vehicles Domestically these anti terrorist devices can be found at Federal Reserve banks nuclear power plants refineries military and utilities bases municipal 12 Intertex Barriers designs and installs deployable road blocking barricades that can stop a speeding truck laden with explosives from being delivered into the front lobby of a building This is accomplished using a control system heavily comprised of products offered by AutomationDirect many remain fully functional Typically the barriers are deployed by security personnel via operator panels These operator panels are sloped front consoles equipped with 22mm _ pushbuttons indicator lights keyed switches and a mushroom style emergency pushbutton TETEN Operator Console A main hydraulic power unit fluid flow and hydraulic energy in accumulators for instant use The stored generates stores high pressure feature of the memory module was utilized to date and information for data logging input and time stamp output changes In the event of an incident data was readily available as a contact sequence histogram The PLC stored several days of data before being overwritten Color touch panels located in the master se
57. resulting new controllers designed to address the 20 applica tions combine the best PLC features with the best PC features Industry ana lysts named these devices programmable automation controllers or PACs In their Programmable Logic Controllers Worldwide Outlook study industry research firm ARC Advisory Group identified PAC characteristics The cri teria characterize the functionality of the controller by defining the software capa bilities Single multi discipline develop ment platform incorporating common tagging and a single database for access to all parameters and functions Because PACs are designed for more advanced applications such as multi domain designs they require advanced software In order to make system design efficient this software must be one integrated software package instead of disparate software tools Open modular architectures that mirror industry applications from www automationnotebook com machine layouts in factories to unit Operations in process plants Because all industrial applications are cus tomized the hardware needs to be mod ular so the engineer can pick compo nents Employ de facto standards for network interfaces languages etc such as TCPIP OPC amp XML and SQL with enterprise networks is critical for queries Communication modern control systems Although PACs include an Ethernet port the software for communication is the key
58. rs across the width of a human hair e You could fit more than 30 million 45nm transistors onto the head of a pin which measures approxi mately 1 5 million nm 1 5 mm in diameter e More than 2 million 45nm transis tors could fit on the period esti mated to be 1 10 square millimeter in area at the end of this sentence e A 45nm transistor can switch on and off approximately 300 billion times a second A beam of light travels less than a tenth of an inch during the time it takes a 45nm transistor to switch on and off 45nm Size Comparison e A nail 20 000 000nm A human hair 90 000nm Ragweed pollen 20 000nm Bacteria 2 000nm Latest Intel transistor 45nm Rhinovirus 20nm Silicon atom 0 24nm Fun Facts from Intel Corporation website www Intel com 19 Tech Thread Control Plartorms WAUTOMATIONDIRECT Welcome PAC Moving on to the next generation controller by Todd Walter Reprinted with permission from ISA Intech og on to any industrial control discussion forum and you will read passionate debates about the advantages and disadvantages of programmable logic controllers PLCs compared to PC based control Amongst the PLC PC debates there most likely were some threads discussing PACs which begs the question What the heck is a PAC PAC programmable automation controller a new acronym stands for and it describes a new generation of industrial controlle
59. rs that combine the functionality of a PLC and a PC Traditional PLC vendors use the PAC moniker to describe their high end systems as do PC control companies in an effort to explain their industrial control platforms As the technological differences between PC and PLC wane with PLCs using commercial off the shelf hardware and PC incorporating real time operating systems PACs further blur the line between different control systems So is PAC a harbinger to end the PC PLC debate or simply another contender for systems control applications To understand the relevance of PACs it is important to review the history of industrial control PLC s early years In the 1960s engineers performed industry control using large banks of mechanical relays The I O for a control system was hard wired into electrical cabinets where mechanical relays were wired together to create interdependencies between digital inputs and digital outputs These systems were complicated hard to modify prone to failure and a large strain on design and maintenance resources 20 late In the 1960s Bedford Associates proposed a new system called Modular Digital Controller MODI CON which used a central processing unit CPU to perform digital logic and interface with digital inputs and out puts The first PLC MODICON 084 efficiently performed digital operations and digital control It also greatly sim plified control system design modif
60. rt with 7 slaves per master The D2 230 can not be expanded beyond the local rack Question Can I override the inputs and outputs in a DL205 PLC 24 7 a p Ci F m a a r a k E T E E E a Maa EH i ti Ste bose Pons ea 8 Select the bit to be overridden and use the on off button to change the state of the bit NOTE Be sure to disable all override bits before returning the PLC to service The D2 230 does not support override You can turn bits on or off using Data View Inputs bits will only be overridden for a single scan since the PLC will update the image register on the next scan and change them back to their actual state NOTE Only inputs can be overridden using this method The outputs will be the result of the rung that controls them As another method you can directly control out puts by loading a program that consists of an END statement only Using Data View you can select the bit and use the on off button to change the state You cannot control inputs using this method Question How can I reset my processor back to factory defaults Answer Resetting the processor to factory defaults is a two step process First clear the processor memory by selecting PLC gt CLEAR PLC MEMO RY from the DirectSOFT menu Next initialize the scratchpad by selecting PLC gt SETUPsINITIALIZE SCRATCHPAD NOTE Initializing the scratchpad will reset the system V memory to default and will clear
61. rt Allen Bradley DF1 protocols when used with the EA MG SP1 Communication option module C more Micro will now with Allen Bradley communicate SLC5 03 5 04 5 05 and Micrologix 1000 1200 and 1500 PLCs in half and full duplex The new drivers also allow full duplex communication with Allen Bradleys PLC5 Communication cables for connection to A B PLCs are available for 20 00 To learn more about C more Micro go to http c moremicro automationdirect com Fusible and Non Fusible Disconnect Switches from AutomationDirect AutomationDirect offers 600 VAC 250 VDC heavy duty fusible and non fusible disconnects from Ferraz Shawmut Meeting UL98 standards the SIRCO and FUSERBLOC series are designed with the latest disconnect tech nology available make and break power circuits under load and are UL CSA CE and IEC rated A wide array of handles is available to meet OSHA padlocking NEMA configurations defeater options and NFPA 79 requirements The SIRCO switches and accessories starting at 57 are available in 30 800 amp ratings Available defeatable pistol handles automatically re latch when the panel requirements door is closed eliminating the need for tools to reset the latch FUSERBLOC fusible disconnects and accessories starting at 85 break up to 200 amps and use double break contacts per pole isolating the fuse while the switch is in the OFF position Used with class CC or J
62. s current operated switches offer higher performance with a field adjustable time delay feature to minimize nuisance trips the 1 value in automation Copyright 2007 AutomationDirect Cumming GA USA All rights reserved l A Product Description AC current transducer fixed core selectable 0 10 0 20 0 50A input ranges 0 10VDC output AC current transducer true RMS split core selectable 0 2 0 5A input ranges 4 20mA out AC adjustable current switch fixed core single 1 150A input range 240VAC DC output AC adjustable current switch split core multi input ranges from 1 75 to 200A 30VDC out AC adjustable current switch fixed core multi input ranges time adjustable 1A 240VAC out AutomationDirect prices are May 2007 prices Prices subject to change without notice For complete information or to order 5 year warranty Split core models available for easy retrofit applications AutomationDirect Price Part Number ACT050 10 F 154 00 ACTR005 42L S 63 00 ACS150 AE F 79 00 ACS200 AD S 83 00 ACSX200 AA F visit www automationdirect com currentsensors VWAUTOMATIONDIRECT www automationdirect com 1 800 633 0405 Automaton vote Look SNMMEeELr z007 ISSE Mine Automation NOTEBOOK Our guarde TO pracheal PIOAYCTS 7ECANOIO9 ES and applicatons Contributors Publisher Tina Crowe Managing Editor Joan Welty Feature Editor TJ Johns Design Mana
63. ses and publishing data to the Web The big problem with this type of setup is these systems are often diffi cult to construct troubleshoot and maintain The system engineer often ends up with the unenviable task of incorporating hardware and software from multiple vendors which poses a problem since the equipment is not designed to work together Building a controller With no clear PC or PLC solution engineers with complex applications worked closely with control vendors to develop new products They requested the ability to combine the advanced software capabilities of the PC with the reliability of the PLC These users helped guide product development for PLC and PC control companies The software capabilities required not only software advancements but also an increase in the hardware capabil ities of the controllers A positive out come of the dot com bubble was a dra matic increase in processor speed net work reliability and communication technology With the decline in world wide demand for PC components semi conductor vendors began to redesign products for industrial applications Control vendors now incorporate indus trial versions of floating point proces sors dynamic random access memory non spinning memory storage and fast Ethernet chipsets into industrial control products This enables vendors to devel op more powerful software with the flexibility and usability of PC based control systems The
64. solenoids T hon EN OER ONL jy motor branch circuit protection Aa ARR g By et the 1 value in automation WA D E r o cee f Copyright 2007 AutomationDirect Cumming GA USA All rights reserved U TO M ATI O N R E CT a www automationdirect com fuses www automationdirect com 1 800 633 0405 WMS series of supplementary protectors from Eaton Cutler Hammer to protect against short circuits and overloads starting at 8 50 U S 250 600 VAC rated current limiting Edison Fuses replace more expensive competitors fuses RHINO DC switching power supplies with 3 year warranty start as low as 56 U S E T N e UL 1077 recognized e Full line of accessories e Class CC for lighting and heating loads small motor circuits e Class J for inductive loads including motor and motor branch circuits e Class RK for AC power distribution lighting e PSM metal series in 12 and 24 VDC adjustable output models from 78 to 600W e PSP plastic housed ultracompact series in 5 12 and 24 VDC models up to 8A output current www automationdirect com circuit_protection www automationdirect com fuses www automationdirect com power Product Snapshots VAUTOMATIONDIRECT AboutPLCs com is all about PLCs AutomationDirect s newest product focused Web site features PLCs AboutPLCs com pulls together infor mation on the specification selection configuration and application of PLCs Find links to automation sites
65. sure level and temperature switches the PLC program monitors the pumps to prevent operation outside safe parameters The PLC sequences pump starts to reduce facility power amperage draw and to distribute pump wear evenly among multiple pumps Any power unit problems are reported by a warning indicator on the operator panel These systems must operate unattended in extreme environmental conditions from the coldest tempera tures at US Air Force bases in Alaska to the hottest temperatures at the US Embassy in Cairo Egypt The first generation of hydraulic units used one two or_ three DirectLOGIC DLO5 PLCs in master slave configurations The ability to expand the system incrementally to match the application provided the best solution at the lowest cost The PLC memory module D0 01MC was a convenient way to make changes to the program at Intertex Barriers and simply send the module to the site to be Anti terrorist barriers are capable of stopping vehicles running 50 mph Once stopped the vehicle is inoperable Three dimensional drawings of the barriers deploying stowing converted into graphics that show were the barriers raising and lowering during operation The latest generation hydraulic units use DirectLOGIC DL06 PLCS Smaller systems use a single PLC E ie swapped out The real time clock While larger systems use up to three 4 _ T a i b Eai Yahi A Tiiu rt e Ta Bolla
66. tenance Although 80 of applications incorporate simple digital and analog control engineers creating the other 20 of the applications relentlessly push the capabilities of their control sys tems These engineers require higher loop rates advanced control algorithms more analog capabilities and better integration with the enterprise network In the 80s and 90s these 20 per centers evaluated PCs for industrial control The PC provided the software capabilities to perform advanced tasks offered a graphical rich programming and user environment and utilized commercial off the shelf components allowing control engineers to employ technologies developed for other appli cations They now could use Intel float ing point processors high speed I O busses such as PCI and Ethernet non volatile data storage and graphical development software tools The PC also provided unparalleled flexibility software and highly productive advanced low cost hardware However PC based control was not perfect so while engineers used the PC when incorporating advanced func tionality like analog control and simula tion database connectivity web based functionality and communication with third party devices the PLC was still king for control The main problem with PC based control was manufactur ers did not design standard PCs for 1 2 TETETETETETT Automaton vote Look Symmer zoo7 Issy wre ru
67. that physically open and close EMRs arc when they interrupt current This is usually beneficial to the relay but it may cause nearby equipment to malfunction if its sensitive to radio frequency interference RFI On the other hand electromagnetic interference EMI caused by relays isn t an issue unless EMI sensitive equipment is installed Good EMRs their electromagnetic fields Otherwise they in close proximity are designed to contain would be highly inefficient SSRs are indicated primary requirement is the ability to where the perform for tens of millions of operations or more Also they re often specified where silence is important If arcing or RFI must be avoided at all costs SSRs are better In applications where a circuit must be completely on or off with minimal on state voltage drop or no danger of injury or damage from leakage current the electromechanical relay is the only choice EMRs also are best if heavy surge currents or spike voltages are anticipated or known to occur In some applications the relay type selected is mostly a matter of personal preference But avoid the pitfall of trying to adapt one type to execute a job better performed by the other This advice is often ignored because of personal bias or a reluctance to ask for help implement relay manufacturers Many applications specialists who welcome the opportunity to help select the best product for the particular circu
68. tionDirect launches new line of current sensors Product Snapshots 6 AboutPLCs com Learn AutomationDirect com Allen Bradley DF1 added to C more micro Fusible and Non Fusible Disconnect Switches Cover Story 8 Made in America Opinions abound but the facts show U S manufacturing to be a global powerhouse evolving to meet tomorrow s changing needs Feature Story 12 Anti terrorist barriers help protect facilities Technical Review 15 Electromechanical relays versus solid state Each has its place Business Notes 17 Goings On in the Automation Industry Technology Brief 18 Semiconductor breakthroughs promise smaller faster chips Tech Thread 20 Welcome PAC Moving on to the next generation controller FYI 24 DL205 frequently asked questions The Break Room 26 Best in Show Brainteasers New Product Focus WAGs MEW a WAUTOMATIONDIRECT AutomationDirect launches new line of current sensors utomationDirect announces the addition of current sensors to its product offerings The AcuAMP series is a family of high performance current sensors offering outstanding features flexibility and durability Backed with a five year warranty the complete line of current sensors transducers and switches will provide dependable service for virtually any application The ACT series current transducers available in split core and fixed core models has jumper selectable current inp
69. tor 1 N O contact GCX1100 IEC devices and incandescent or LED AutomationDirect Price Part Number Allen Bradley Price Part Number 800EM F2 800E 2LX10 22 mm pushbutton flush 6 25 30 72 amp 30 mm pushbutton flush 1 6 75 37 1 0 N O contact HT8AAGA 800T A1D1 led stacklight ent 2avacioc 119 25 2y 226 69 E26XWWL392W V2 855TS B10D3D5D4 re April 2007 Price List Allen Bradley prices are from Publication A115 PL002A EN P August t prices For more information or to order visit www automationdirect com pushbuttons oE ONL bi x Koa BY Poy A Sa nm m 5 13 the 1 value in automation P Sy Rigid and flexible wire duct an e All rigid duct comes in 2 meter lengths with cover sold individually or in value packs e Flush cover design holds 10 12 percent more wires than traditional designs e Flexible duct braided sleeving and duct accessories available www automationdirect com wire_duct Copyright 2007 AutomationDirect Cumming GA USA All rights reserv WAUTOMATIONDIRECT www automationdirect com 1 800 633 0405 General purpose relays and timers add control d isolation to your application i l ma Se F A r ih ey iF ae 1 3i 1 Ve i Lk i ji H i D B bai E T pa i a iw or a e Cube and card relays up to 16A rating e Solid state relays up to 25A rating e Fuji 1 16 and mini DIN timers start at 31 e Fu
70. umming GA USA All rights reserved VWAUTOMATIO yw aboutplics com directlogic Use PLCs HMI Drives and other electrical components from AutomationDirect to implement simple low cost machine control DirectLOGIC programmable controllers range from nano sized fixed I O units to modular systems with thousands of I O Most DirectLOGIC PLC CPUs include a communications port that supports serial Modbus RTU protocol DirectLOGIC PLCs start at 99 00 U S for a 14 I O fixed unit Shown to the left is a DLO6 36 I 0 model with option cards installed in its expansion slots The C more family of operator panels are the perfect interface for DirectLOGIC PLCs C more Micro Graphic panels shown at left have a 3 1 screen for graphics and text and are available in touch 189 U S and non touch 139 U S models Their low cost plus FREE downloadable configuration software make it a no brainer to add HMI to your application For larger applications C more touch screen panels starting at 425 U S are available in 6 grayscale or color STN panels TFT color units are available in 6 8 10 12 and 15 sizes The configuration software 129 U S is so easy to use you ll be creating screens in minutes www sureservo com Implement simple low cost motion control using a daisy chained serial link between a PLC and multiple SureServo AC servo systems The SureServo drives include an on board indexer which can acce
71. ut ranges and industry standard 4 20 mA or 0 10 VDC outputs This factory matched and calibrated single piece transducer is more accurate than traditional two piece field installed products ACT series current transducers are ideal for remote monitoring and software alarms Split core models make using portable data loggers easy and simple connection enables power consumption or other motor status display For safety 4 and to eliminate voltage drop the output is magnetically isolated from the input The ACT series current transducers are UL cUL and CE approved and prices start at 73 The ACTR series current transducers combine a current transformer and a rue RMS signal conditioner into one unit Available with 4 20 mA output ACTR current transducers utilize True RMS technology for accuracy on distorted waveforms such as VFD or SCR outputs These transducers are an excellent way to monitor motor and load operation via VED outputs ACTR current transducers also provide accurate measurement of phase angle fired or burst fired SCRs giving faster response than temperature measurement True RMS sensing is the most accurate way to measure power supply or ballast input power ACTR current transducers are UL cUL and CE approved and prices start at 125 The new AcuAMP series also includes current operated switches equipped with LED status indication The ACS150 series current operated switches combine a current transformer signal conditioner
72. xperience and awards in their sophomore 2006 2007 season Teams compete in alliances of three in a game that changes every year Robots are built in 6 weeks from a common kit of parts provided by FIRST and can weigh up to 120 lbs excluding battery This seasons game dubbed Rack n Roll focused on machine dexterity and accuracy Students robots were designed to pick up and hang inflated colored tubes on pegs configured in rows and columns on a 10 foot high center rack structure Extra points are scored by robots being in their home zone and www automationnotebook com lifted more than 4 or 12 off the floor by another robot before the end of the 2 minute and 15 second match The Forsyth Alliance s robot named Otto participated in two Regionals this year at the Peachtree Regional in Atlanta held March 15 17 the team s alliances which vary from match to match won all of their 8 pre liminary matches This performance earned the Forsyth Alliance the number one seed for that Regional s final matchups but by then their opposing alliances strategies boiled down to Block Otto Although not a winning finalist there the team was awarded the Peachtree Regional s Imagery Award for the second consecutive year Two weeks later the Alliance put in another strong showing at the Palmetto Regional in Columbia SC placing 10th after all teams completed 10 matches Again they competed in the final

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