Automation Notebook: Online Technical Magazine Issue 19 · Bryant Manual Motor Controllers starting at $21.50 • Lockout / Tagout capability • 30, 40 and 60A up to 600 VAC

www.automationdirect.com

1-800-633-0405

Go online or call to get complete information,request your free catalog, or place an order.

Motor feeder shortcircuit and groundfault protection

Motor disconnecting means (NEC430.101-430.113)

Motor branch-circuit short circuit protection(NEC 430.51-430.58)

Motor controller(NEC 430.81-430.91)

Motor overload protection(NEC 430.21-430.44)

OSHA Lockout/tagout disconnect (NEC 430.81-430.91)

ControlTransformer

PLC I/O ContactorCoils

Relays

UL 1077Supplementary Protectorsstarting at $8

UL 248General Fusesstarting at $1.75 (5-pack)

Ensure that your equipment is safeguarded at everypoint in the power distribution network withhigh-quality, cost-effective circuit protection anddisconnection devices that meet UL standards.They’ll pay for themselves in no time!

• Rated current up to 800A, max 600V• Standard and high-interrupting capacity types

• Non-fusible and fusiblerotary disconnectswitches

• Make/break loads upto 800 amps

Class T, RK5, RK1 andClass J current limitingshort circuit protectionup to 600A

• DIN-rail mounted• Up to 40 amps• 1, 2, or 3-pole available• 10kAIC @ 277/480VAC

• DIN rail mountable• Full line of auxiliary switches, alarm switches

and padlock lockout accessories• B trip curve 6 to 60 amps• C trip curve 0.5 to 60 amps• D trip curve 0.5 to 40 amps

• Class CC, general purpose class M (Midget) andsmall dimension glass and ceramic fuses

• Ideal supplementary protection up to 30 amps forbranch circuits and end of line equipment

UL 489MCCBsstarting at $166

UL 98Disconnect Switchesstarting at $75

UL 489Miniature CircuitBreakers, up to 40Astarting at $16.50

UL 248Current Limiting Fusesstarting at $31.50 (10-pack)

Bryant ManualMotor Controllersstarting at $21.50

• Lockout / Tagout capability• 30, 40 and 60A up to 600 VAC• 2-pole and 3-pole switches• Quick make, slow break design• UL Listed as “Suitable as Motor Disconnect” under UL 508

• 35mm DIN rail mountable or direct mountable• Loads from 16 to 125 amps• IP20 degree of protection

UL 508Load Switchesstarting at $22.50

3

Automation Notebook Winter 2011 Issue Nineteen

www.automationnotebook.com

Contributors Editor’s Note Table of ContentsSo, we’ve almost made it to the

end of winter 2011. What a winter ithas been, too. When “Snowpocalypse”hit the south in mid-January, much ofGeorgia was shut down for a few days.Snow accumulations in excess of sixinches in most places and ice over aninch thick on some of the highwaysmade things quite treacherous. (Youknow it’s bad when UPS and FedExcan’t make their deliveries.)

The southern states are not accustomed to rough weather conditions like we experienced. But, weforged onward. With much apprecia-tion for the hard work of our logisticsteam, and help from UPS and FedEx,we shipped a tremendous backlog oforders when services resumed.

With the worst snow storm to hitthe south in 18 years behind us, now welook forward to the sunshine and warm,beautiful months ahead.

We have a great issue ofAutomation NOTEBOOK ready foryou. This issue is filled with informa-tion about our latest products and lineextensions. Brian Elliott concludes histwo-part series on Electrical Arcs; ourStudent Spotlight focuses on LarryMay, a student at Southern PolytechnicState University who has developed avolleyball setting and serving machine.Our cover story, from contributingwriter Jack Smith, addresses the topic ofwhether to upgrade control systems or not.

You’ll also find informative technical articles, and we provide somemental relaxation in the Breakroom. Besure to let us know what you thinkabout Automation NOTEBOOK. Welook forward to your comments.

TJ JohnsCoordinating [email protected]

New Product Focus 4ProSense line expands withThermocouples, RTDs, andExtension Wire

Product Snapshots 6Sensors for food and beverage industry,Standard CPUs added to CLICK PLC line,C-more Micro 4-inch TFT Touch Panel,NITRA tubing and hose, safety lightcurtains and limit switches, Class Tfuses, Compact Pneumatic Air Cylinders,Stellar full-featured soft starters

Cover Story 8Is it Time to Upgrade YourControl System? Are yourmachine or robot control systemsgood enough, or should youmake a change?

System Integrator Corner 12PCA provides complete turnkey,cost-effective control systemsolutions for a variety ofindustries

User Solutions 16Advanced Automation, LLC takesbaking to the next level

Student Spotlight 17The future of technology

Tech Brief 18Electrical Arcs (Part 2 of a 2-part series)

User Solutions 23PLCs give Wastewater PumpingStations a Lift

FYI 24Safety Light Curtains

Business Notes 29Goings-on in the industry

Break Room 31BrainTeasers

Publisher Tina Gable

Managing Editor Joan Welty

Coordinating Editor TJ Johns

Design Manager Justin Stegall

Contributing WritersBrian Elliott

Lenny FilipkowskiJohn Keller

Chip McDanielJeremy Poarch, P.E.

Jack Smith

CONTACTSAutomationdirect.com Inc.3505 Hutchinson RoadCumming, GA 30040

Phone . . . . . . . . . . 1-800-633-0405or 1-770-889-2858

Fax . . . . . . . . . . . . . 1-770-889-7876

Monday - Friday 9 a.m. to 6:00 p.m. EST

www.automationdirect.comCopyright 2011, Automationdirect.com Incorporated/AllRights Reserved. No part of this publication shall becopied, reproduced, or transmitted in any way withoutthe prior, written consent of Automationdirect.comIncorporated. Automationdirect retains the exclusiverights to all information included in this document.

If you are a non-subscriber andwould like to be included in the next mailing of AutomationNotebook,please visit:

http://www.automationnotebook.com/freestuff.html on the AutomationNotebook Web site, and complete thedetails. You can also request FREE stuff,including our catalog and our CD-ROMfeaturing the entire catalog and demosoftware. If you provide your emailaddress, we will send news and productinformation from time to time as well.

For those who prefer to speak withus in person, please call 1-800-633-0405x1845. Thanks for your interest, and welook forward to hearing from you.

Your guide to practical products, technologies and applications

New Product Focus

4

ProSense lineexpands withThermocouples, RTDs,and Extension Wire

he ProSense line of processmeasurement devices nowincludes type J and type K

thermocouples, more varieties of RTDsensors, and extension wire.

Thermocouple probes with connection heads feature cast aluminumNEMA 4 screw covers with captive gasket and stainless steel chain. The ¼”diameter probes are available with tem-perature sensing ranges of 32 to 1,330°F(Type J) or 32 to 1,700°F (Type K).Welded-style probes, in 6”, 12” and 18”lengths, are bendable to adapt to installation requirements; spring-loadedprobes are available in 4”, 6” or 12”lengths. Prices start at $42.00.

Thermocouple welded and spring-loaded probes with ½” x ½” hex nipplesallow easy replacement of existingprobes and easy connection to wiringjunction boxes. Available in 6”, 12” or18” lengths, the ¼” diameter weldedstyle is bendable to adapt to installationrequirements, while the spring-loadedstyle provides positive tip contact inthermowells. Prices start at $33.75.

Available thermocouple probeswith pre-attached plugs feature 1/8” or1/4” diameter sheaths in 6” 12” or 18”lengths; thermocouple probes with leadwire transition come with a six-footheavy-duty lead wire. Temperature sens-ing ranges are 32 to 970°F or 32 to1330°F (Type J) and 32 to 1700°F(Type K). Prices start at $17.25.

Type J or K thermocouple

adjustable immersion sensors, ideal forplastics processing applications, featurea 32 to 900°F temperature range and 4,6, or 10-foot lead wires; the spring and armor adjustable styles allow forvariable immersion depths. Adjustableimmersion sensors start at $16.00.

Bolt-on ring sensors are ideal fornozzles, extruder barrels, die heads,molds and other surface-mount sensingapplications. Thermocouple bolt-onring sensors with a 32 to 900°F temperature sensing range start at$15.25; RTD bolt-on ring sensors witha -58 to 572°F temperature sensingrange are available for $54.00.

RTD probes feature ¼” diameterstainless steel sheaths with 100 ohmplatinum three-wire elements. With atemperature sensing range of -58 to572°F, the probes are available in 6”,12” or 18” lengths. Models availableinclude welded and spring-loadedprobes with cast aluminum NEMA 4connection head and captive gasket, ¾”NPT conduit opening and stainless steelcover chain; probes with ½” x ½” hexnipples are available in welded andspring-loaded styles, allowing for easyreplacement of existing probes and connection to wiring junction boxes.Also available are probes with pre-attached three-pin plugs for quickand easy wiring connection, as well asprobes with lead wire transition or M12connections. RTD probes start at$29.00. RTD thermowells start at $23.50.

ProSense RTD sanitaryClean-in-place probes are designed tomeet the stringent requirements ofH T S T pasteurization systems. These 4-inchprobes are available in the standard ¼”diameter or with a 3/16” diameterreduced tip for greater durability inhigh-viscosity applications. The stainlesssteel probes have a -58 to 400°F temperature sensing range. Clean-in-place probes start at $89.00.

Two-conductor thermocoupleextension wire for types J and K, in standard ASTM/ANSI colors, are available in convenient 50-foot and100-foot lengths starting at $15.00.Also available is RTD extension wirewhich offers superior performance compared to “off-the-shelf ” cable.Starting at $21.00, the three-conductorwire is available in 50-foot and 100-foot lengths.

Accessories for thermocouples and RTDs include: thermowells, compression mounting fittings, bayonetadapters and thermocouple and RTDconnectors. See the full ProSense line at:www.automationdirect.com/temperature-sensors

What’s New

T

“Behind every great man is a womanrolling her eyes. ”

– Jim Carrey

Over 120 thermocouple and RTDsensors are pre-built stock items -

order today, they ship today!*


1-800-633-0405


NEW! Thermocouples starting at $1525

Get the most popular thermocouple probe configurations at practical direct prices.

• Probes with connection head• Spring-loaded probes with connection head• Probes with hex nipple• Spring-loaded probes with hex nipple• Probes with attached plug• Probes with lead wire transition• Adjustable immersion thermocouple sensors• Bolt-on ring thermocouple sensors

• Probes have type J or K thermocouple elements to meet manytemperature sensing applications

• Made in the USA• RoHS

NEW! Extension Wire 50 ft. and 100 ft. lengths

• Thermocouple extension wire for Types J and K with standardASTM/ANSI color coding

• RTD extension wire specially constructed to offer superior performancecompared to “off-the-shelf” cable

NEW! RTD sensors starting at $2900

These 100 ohm platinum RTDs are available as 3-wire elements (except where noted) with Class A accuracy.

• Probes with connection head• Spring-loaded probes with connection head• Probes with hex nipple• Spring-loaded probes with hex nipple• Probes with attached plug• Probes with lead wire transition• Bolt-on ring RTD sensors• Probes with M12 cable connector (3- and 4-wire elements)• Sanitary Clean-in-Place (CIP) probes

Thermowells starting at $2350

• Thermowells for RTD probes with M12 cable connector• NEW! Thermowells for spring-loaded thermocouple

and RTD probes

Accessories• Compression mounting fittings for temperature probes• Bayonet mounting adapter for temperature sensors• Thermocouple and RTD connectors

* When ordered by 6 pm EST, with company P.O. or credit card.See Web site for complete details.

For complete details or to order, visit:www.automationdirect.com/temp-sensors

Product Snapshots

6

Sensors for food andbeverage industry

A new line of food and beveragesensor products includes AC and DCproximity and photoelectric sensors andquick-disconnect sensor cables.Compliant with the IP69K standard,the sensors withstand washdown condi-tions up to 212°F and are constructed ofFDA certified materials.

The PFM 12mm and PFK 18mmproximity series are sensors with shielded or unshielded stainless steelhousings and M12 quick-disconnectplug with gold-plated pins. Providingcomplete overload protection, eachseries has 10 models available. The PFMseries has a standard sensing distance ofup to four millimeters and extended distance of up to eight millimeters. ThePFK series has a standard sensing distance of up to eight millimeters andextended distance of up to 12mm.Models are available in a choice of 10-30VDC PNP or NPN transistor outputsand normally-open or complementaryoutput configurations. PFM and PFKseries sensor prices start at $35.

The PFT 30mm series of proximity sensors are available in fourmodels with sensing ranges up to22mm. Models are available with

shielded or unshielded housings andnormally-open outputs. PFT seriesprices start at $45.

The VFK 18mm and VFT 30mmseries proximity sensors are availablewith shielded or unshielded stainlesssteel housings and half-inch micro ACquick-disconnect plugs with gold-platedpins. With complete overload protec-tion, each series provides normally-open20 to 140 VAC outputs. VFK seriesprices start at $55 and VFT series pricesstart at $59.

Magnetic proximity sensors areavailable in 12 mm and 18 mm diameters. The shielded 10-30 VDCsensors have a sensing range of up to70mm and a normally-open output.Prices for magnetic proximity sensorsstart at $44.

Two series of 18mm food and beverage photoelectric sensors have alsobeen added. The FF series photoelectricsensors are available in 30 models andfour styles: diffuse, polarized reflective,through-beam, and retro-reflective (fortransparent objects). Sensing distancesrange from 100mm to 20 meters. TheFFRS series diffuse photoelectric sensorswith background suppression are available with adjustable maximumreading distances – 30 to 130mm and60 to 100mm for shiny objects. Sensorsare equipped with LED status indicators; yellow indicates output whilegreen indicates teaching function. FFseries prices start at $65; FFRS sensorsstart at $79.

IP69K-rated cables are also available. Industry standard axial andright-angle M12 or half-inch micro connectors with open leads are availablein five and 10-meter lengths. M12screw-lock patch cables are also availablein axial and right-angle models and0.3m to five-meter cable lengths. Pricesfor cables start at $12.50.

See the full line of food and beverage sensor products at:www.automationdirect.com/food-beverage-sensors

Standard CPUs added toCLICK PLC line

The CLICK family of micro brickPLCs now includes standard CPU units.The new units feature eight discreteinputs and six discrete outputs, availablein four combinations of built-in I/Otypes. In addition to two RS-232 RJ12communication ports, the standardCPU units are equipped with one RS-485 communication port and feature real-time clock and battery back-up for the internal SRAM. Sold separately, the battery allows data to bestored for up to five years.

CLICK Standard CPU units start at $99. CLICK’s user-friendly programming software is downloadablefor free at www.automationdirect.com,providing the tools, layout, and interactivity needed for quick and intuitive program development. In addition, an online help file providesinformation to help users get acquaintedwith the software quickly.

To learn more about the newStandard CLICK CPU units, visitwww.automationdirect.com/click-plcor call 800-633-0405.

C-more Micro 4-inch TFTTouch Panel

The C-more Micro-Graphic familyof operator interfaces now offers a 4-inch TFT color touch screen HMIpanel. The panel features a 320 x 240dot display; 32,768 colors provide clearand colorful graphics for vibrant and

Press Releases

7



intuitive screens. The free programmingsoftware offers the choice of using built-in objects or importing custom graphics. The user can create and savecustom objects and graphics to softwarelibraries for fast and easy access frommultiple projects. The 4-inch touchpanel is equipped with a standard TypeB USB programming port, a serial communications port which supportsthe most popular PLC drivers, and fivedurable function keys with LED indicators. The unit offers 3.2 kB memory, LED backlight, multistatebitmap support and Windows font support. C-more Micro’s 320 x 240screen allows either portrait or landscapeinstallation when space is a concern.Backed by a two-year warranty, thepanel is priced at $329. Learn more atwww.automationdirect.com/C-more-micro

NITRA line expands tubingand hose offering

New tubing and hose options havebeen added to the NITRA line of pneumatic components, including

bonded straight and coiled styles.Available in 50-foot lengths,

NITRA bonded polyurethane tubing ismade by a continuous bonding process,resulting in a strong, organized, color-coded package with flexibility and kinkresistance. The shore A 98 hardness rating provides tight outside diametertolerance, making it ideal for use withNITRA push-to-connect fittings.Available in 5/32 to ½-inch and 4mm to12mm sizes, bonded straight tubingstarts at $13.

NITRA polyurethane coiled tubing has also been added. Coiled tubing is available in single, double, andtriple bonded configurations with double and triple coils in contrastingcolors. Available in three workinglengths, and in sizes ranging from 5/32-inch to 3/8-inch and 4mm to 10mm,prices start at $4.50.

The addition of pneumatic airhoses includes reinforced polyurethanestraight, as well as coiled and reinforcedcoiled styles. Available in quarter-inchand 3/8-inch sizes, the hoses are fittedwith one rigid and one swivel fitting,based on hose inside diameter.

Reinforced polyurethane hosecomes in 25 and 50 foot packages. Witha shore A 85 hardness rating, the hose isstrong, flexible and kink resistant. Pricesstart at $11.50 for a 25-foot package.

NITRA coiled and reinforcedcoiled hoses are available in eight, 12and 16-foot working lengths. Coiledhose has a shore A 98 hardness ratingwhile the reinforced coiled hose has ashore A 85 hardness rating. Prices startat $12.50 for coiled hose and $23 forreinforced coiled hose.

See the full line of NITRA pneumatic tubing and hoses atwww.automationdirect.com/pneumatic-tubing-hoses

New safety light curtains andlimit switches

Machine safety devices for use inindustrial applications are now available.Two series of safety light curtains (activeoptoelectronic protective devices) aredesigned for human protection andproduct/machine safety where risks

cannot be eliminated by machine designand the process might require frequentand open access during operation.

The YBB-14 series has a 14mmsensing resolution for finger-size protec-tion and an operating distance of up to3.5 meters; protective heights rangefrom 142 mm to 1,045 mm. The YBB-30 light curtains series has a 30 mmsensing resolution for hand protectionand an operating distance of up to 12meters; protective heights range from279 mm to 1,827 mm.

All safety light curtains have Type 4and Cat 4 PL e safety ratings and areIP65 rated. Light curtain sender pricesstart at $250.00 and receiver prices startat $275.00. Mounting brackets areincluded with each unit and additionalmounting accessories and protectivecolumns are available.

AutomationDirect has also added aline of machine guarding safety switchesto detect unsafe conditions and isolatepower. Normally-closed contacts areused for a positive break and redundantnormally-closed contact and normally-open feedback outputs are available.The safety switches cannot be easilydefeated and all units have CE, UL andCSA approvals. Four bases are available:30mm plastic, 50mm zinc alloy, 40mmaluminum and 60mm aluminum. Fourtypes of interlocks are available for common safety applications includingtongue (key), shaft hinge, lever hingeinterlocks and pull cord actuators withreset for emergency stop or without resetfor simple stop. Safety interlock switches start at $15.00 and safety limitswitches start at $12.75.

See the full line of safety productsat: www.automationdirect.com/safety

Continued, p. 14>>

Cover StoryTrends in Automation

Is it Time to UpgradeYour Control System?Are your machine or robot controlsystems good enough, or shouldyou make a change?

By Jack Smith

he machines and robots youbuild work well. You’ve kept upwith periodic improvements.

Most of your support calls are predictable. Why rock the boat?

As a machine or robot builderOEM, you understand the favorableeconomics of selling machines or robotsfor which your company has recoveredits initial investment, particularly in thecontrol system. Your margins are good,but are they as good as they could bewith a control system upgrade? Maturity Indicators

Most of the factors affecting decisions to upgrade can be categorizedas performance related. However, otherdecision criteria include communicationrequirements, reliability, and safety.

Does the machine still do what itwas designed to do as efficiently as itcould to satisfy customers’ productionrequirements? “An automation systemupgrade should increase OverallEquipment Effectiveness (OEE), oftenan important benefit for our customers,” says Mel Bahr, executivevice president at MGS Machine(www.mgsmachine.com), MapleGrove, Minnesota, in Control Design’sOctober 2010 cover story, “Time toMake a Change.”

MGS Machine builds top and horizontal-load cartoning machines aswell as product feeding equipment(Figure 1). “Automation upgrades oftenmake it easier to change products, crucial to our contract packaging clients,and increases in speed are also often realized,” adds Bahr in the cover story.

“Other reasons why we upgradeour automation systems periodically are

improved HMIs and help screens, ability to control robots from a commonmachine control platform, improvedservo performance and control, betterdata collection and tracking, automateddata transfer to items like printers, andthe need for vision systems and visioninspection,” concludes Bahr in the sameControl Design story.

There are many reasons to upgradeautomation systems says Joe Sebastian,senior systems engineer at Optimation(www.optimation.com), a system integrator servicing robot and machinebuilders along with other customers.“Safety, efficiency, increased availabilityof spare parts, easier or less maintenancerequired, improved connectivity toother systems, higher production capacities, less operator involvementand quicker setup or changeover timeshave all initiated automation upgrades,”he says in the cover story. His companyhas added very basic automation to machines and doubled their production speeds.

“Changeover times are also a hugeconsideration, as new machines canautomate a great deal of the productchangeover process, or even do it on thefly with it being initiated directly froman MES system,” Sebastian notes in thestory. “Usually it is some combination ofall of these factors that add up to an

automation upgrade with an acceptableROI.”Is ‘Old Reliable’ Still Reliable?

“If it ain’t broken, don’t fix it,” is a variation of an old maintenance andrepair adage. Many machine controlcomponents continue to work well even as they approach obsolescence.Evaluating what to keep and what to replace often boils down to reliability, maintainability, and how the components in question affectmachine performance.

Dan Jensen, senior automationengineer at Nelson Sales Corp(www.nelsonsales.com) in Muskego,Wisconsin, says in the same ControlDesign cover story, “The real questionis, does the machine work well overall.In the case of older hydraulic systems,their on/off nature and abrupt directional or velocity changes oftenwear out parts and mean headaches formaintenance personnel.”

According to Jensen, replacing theold directional valve with a newhydraulic proportional servo valve/motion controller combination can prolong the life of a machine due toreduced mechanical stress. Also, usingbetter closed-loop controls can oftenenhance the reliability of some of the older hydraulic and mechanicalcomponents which are still functional

T

8

Figure 1. This work cell from MGS Machine feeds and opens auto-lock bottom, flat-blank, or glue-bottom cartons. The top is closed after a robot loads products into the

carton. (Image courtesy of MGS Machine)


9www.automationnotebook.com

for the application. “The machinebuilder can often cut costs by keepingthe hydraulics and mechanicals, andreplacing just the controls,” Jensenexplains in the cover story.

Jensen did exactly that with a welding system he upgraded for a customer (Figure 2). His company usedthe existing hydraulic system, but itrequired a positioner that could standup to weld spatter. “We added a linear magnetostrictive displacementtransducer for positioning a slide thatheld the assembly being welded, a PLC,an operator screen, and a motion controller,” Jensen explains in the story.

A control system should probablybe upgraded if it’s based on old relaylogic, but what if solid-state controlhardware is discontinued? The Internetmakes supporting just about any legacyhardware or equipment possible, but is it desirable to rely on third-party support?

Obtaining support isn’t necessarilythe primary reason for control systemupgrades, as Jensen suggests. “Does themachine work well now, and will it stay working?” he asks in the ControlDesign story.

Do you remember floppy diskdrives? “Does the computer softwarework with newer laptops, or do youhave to keep an old laptop with specialsoftware on the shelf just in case?”Jensen asks in the story.

The machines may work and thedesigns may still be viable, but at whatcost? If older components have high failure rates, maintaining or supportinga legacy control system can becomecostly. “Failure of obsolete componentsis generally unpredictable and almostalways occurs at the least convenienttime,” says Phil Gilkes in the ControlDesign cover story. Gilkes is director ofproduct support at Intelligrated(www.intelligrated.com), a builder ofmaterial handling equipment in St. Louis, Missouri. “The downtime canresult in significant costs to the end user.”

Additionally, controller ease-of-usecan make selling machines a bit easier.

“Traditionally, robot manufacturersused their own proprietary controller,which was complicated to program andhad to be interfaced with other systemcomponents,” observes Gilkes in thecover story. “Now, complete robotic systems can be controlled by a single,powerful PLC. Customers are far morecomfortable with PLC controls andtend to prefer systems and vendors thatuse them.”

Sometimes, there may be psychologyat work in the use of the expression“new and improved.” But sometimes anew and improved control systems platform will better handle all the newtasks, requirements, and regulations that continue to surface in today’s manufacturing environments.Playing it Safe

Safety continues to be a valid consideration when deciding if a controlsystem upgrade is in order. In theControl Design cover story, RogerRosinski, plant manager at All AmericanPoly (www.allampoly.com) inPiscataway, New Jersey, says “Safetystandards have become more stringentover the years, and older machines generally can be made much safer withan investment in controls.”

The European Machine SafetyDirective (EN ISO 13849-1 or EN IEC62061) is one of the new safety standards global machine and robotbuilders must satisfy. However, safetyupgrades may not present value to anOEM for machines that already meetthe standards required in their markets.

Jensen advocates simplicity. “Asafety-networked architecture has to belarge and duplicated to be cost-effective,” he notes in the cover story. Asan example, he states, “Safety in a robotcell may be easier to do with discretecomponents such as a door interlockand a couple of E-stops.”

A systems integrator suggests anintegrated approach. “An integratedautomation and safety system is theaccepted norm for most industries,” saysSebastian in the Control Design coverstory. “If the existing system is proven

safe, however, then safety is a hard sellby itself. Many old machines don’t havesafety mechanisms built in, so safetycontrols can’t be added without majormechanical changes.”

Gilkes advises in the story, “Themost compelling safety-related reason toupgrade is based on an assessment of thesystem itself to determine whether itmeets with current standards, which canchange as new legislation is developed.”

Safety relays and hard-wired safetyinterlocks may be employed in oldersafety systems to stop the equipment.However, if an emergency stop occurs,the control system could end up in an unknown state when these relays and interlocks cut power to critical components.

Unless compliance with standardsis an issue, safety by itself is typically nota sufficient reason to upgrade a controlsystem, according to system integratorsand OEMs.A Failure to Communicate?

A major advantage to upgradingyour machine control platform is theability to offer modern communicationsfunctionality such as Ethernet, fieldbus-es, wireless, and Web access.

Michael Gurney, CEO at systemsintegrator Concept Systems(www.conceptsystemsinc.com) inAlbany, Oregon, says in the ControlDesign cover story that communica-tions is easier with newer control systems. “With the evolution of com-munication standards, there’s no reasonthat manufacturer to manufacturercommunications can’t be done easily. If you’re considering a hardware manufacturer that’s difficult to interfaceto other automation components, you might want to reconsider using that supplier.”

The ever-increasing need for manufacturing and equipment data isanother significant factor to consider.For example, modern communicationscan allow machine-to-machine, HMI/SCADA, Internet, and enterprise software connectivity. “In any

Continued, p. 10>>

Cover Story cont.

10

Trends in Automation

automated environment, sharing data inreal time is the key to efficient operation,” says Duane Grob in thestory. Grob is the vice president of engineering at Optimation. “Without ameans of sharing and communicatinginformation with other subsystems, allactions are basically reactionary.”

Better data means better informationand better decisions. “Many older systems don’t integrate well with anoverall automated environment,” Grob

adds in the cover story. “Another relateditem is smart I/O communications forgathering more detailed device status.Some device information is simply inaccessible unless smart I/O platformsare incorporated into the overall systemdesign. The data gathered from thesedevices can enable better decisionsabout maintenance, OEE, and system

performance—as well as inform plantpersonnel on repairs needed to continueoperations.”

Many control system components

and platforms are available today with aplethora of communication protocolchoices such as Ethernet and variousfieldbuses. The demand for MES andERP integration is growing among endusers. Some OEMs are offering remoteservice and VPN functionality, whichgreatly reduce the demand on their support staff and lower their customers’maintenance costs. If a control platformcan’t keep up with data demands, it maybe time for an upgrade.Other Considerations

Rick de Jong, general manager,AEMK Systems(www.aemksystems.com), a robot manufacturer in Waterloo, Ontario,Canada comments in the cover story:“The most significant changes inmachine and robot building are controlsand flexibility. Flexibility means amachine or robot should be designedwith product changes in mind. Thismeans less fixed tooling, and a control platform that can be modifiedwith minimal cost and time. Avoid theautomation graveyard by ensuring thatautomated systems can not only beupgraded and modified, but also thatthe technology can be recycled into newapplications.”

Sometimes, the decision comesdown to money. “The overall cost ofownership needs to be considered,”advises Gurney in the story. “Thisincludes maintenance costs, downtimecosts, and the cost of not having something faster, more accurate, and/ormore functional. These costs need to be considered over an acceptable ROI period.”

Where do systems integrators andmachine builders stand on the questionof whether to choose a single supplier, orwork with multiple equipment and

software vendors?In the cover story, de Jong

says, “It’s wise to focus on a single vendor that integrates various products

to one common platform. This reduces integration time and cost, provides faster service and support,reduces the training time, and

Continued from, p. 9

Figure 2. Operators can now enter recipes on the touch screen of this welding machine due toautomation system upgrades.

(Image courtesy of Delta Computer Systems)

eliminates the complexities of multiplevendor interfaces.”

Gurney also advocates vendorstandardization. “We encourage companies to standardize on a singlevendor for similar functions,” he advisesin the Control Design story. “For example, companies should standardizeon a PLC manufacturer, an HMI manufacturer, and a drive manufacturer.This minimizes spare parts and training requirements.”

Jensen offers a different perspective. “Using single-vendor systems usually means sacrificing capability for the sake of a name. Justbecause a manufacturer makes PLCsdoesn't mean their control architecturefor servo control is worthwhile.Nowadays, everything worth usingcomes with an Ethernet interface andwill communicate via various protocols,so being limited to one manufacturerisn’t necessary,” he said in the ControlDesign cover story.

Procurement comes with signifi-cant inherent overhead. Buying from multiple vendors can increase costs thatare not always easy to quantify. Using asingle vendor can help reduce thesecosts. “From a purchasing perspective,the customer only has to deal with onevendor and thus can generally negotiatebetter discounts,” adds Gilkes in the story.

On the other hand, not upgradingis one way to avoid the single-source/multiple vendor debate. “If a machine isold but otherwise performing well, itmay be best to leave it unchanged, providing it continues to meet production and product life cycle requirements,” de Jong sums up in thecover story.



Table 3

Table 2

Table 1

REMOTE ACCESS AND CONTROL BUILT-IN

ALL C-MORE PANELS INCLUDE:

FULL-FEATURED MODELS ADD:

CONNECT TO CONTROLLERS WITH DRIVERS FOR:

12

System Integrator CornerAutomation provides cost savings

PCA provides complete turnkey, cost effective controlsystem solutions for avariety of industriesBy John Keller,Pacific Coast Automation, Inc.

acific Coast Automation, Inc.,located in Modesto, California,was founded in 2008 based upon

the need for a competent, dependable andreasonably priced control system engineer-ing firm, and not just a “controls tech”company which bases its existence on service calls. Since its meager beginning,PCA has seen an almost 500% growthfrom 2009 to 2010, making it a power-house in the controls industry. Majorclients include General Mills, E&J Gallo,The Wine Group, California Dairies,Safeway, Cargill, CertainTeed, and the listgoes on.

While PCA primarily specializes insolutions for the Food and Beverageindustry, we cover a wide variety of areas,including steel manufacturing, plasticproducts fabrication, agricultural products,chemical packaging, water/wastewatertreatment and several others.

PCA offers its customers completeturnkey solutions, setting them apart fromother integration firms. They provide services from conception to completion,which include upfront process consulting,design engineering, CAD drafting,PLC/HMI programming, constructionsupervision, startup support, operator/maintenance training, and follow up services.

In addition to our integration services, PCA, a UL 508A listed panel fabrication facility, designs and builds

custom control panels at our location.PCA also has electrical and mechanicalcontracting partnerships to provide complete solutions from concept to installation and beyond. PCA is a memberof CSIA (Control System IntegratorsAssociation), a global, not-for-profit, professional association for control systemintegration companies.

Some of the application capabilitiesinclude bottling/packaging line controlsystems, wine and beer production, dairyprocessing, CIP (clean-in-place) systems,nut hulling operations, plant utilities,industrial wireless technologies and otherfood/beverage processes. One major part ofPCA’s offerings includes the design andimplementation of OEE (OverallEquipment Effectiveness) systems. In contrast to canned solutions, PCA performs consulting and evaluation services for customers to determine whichvendor’s solution is the best fit for their particular needs. Although it can be confusing and overwhelming for someonenew to OEE, PCA removes the guessworkby utilizing years of experience and vastknowledge so customers can immediatelybenefit from the valuable data that suchsystems can provide.

During these difficult economictimes, many companies look for ways tostreamline operations and become moreefficient. PCA assists customers by evaluat-ing and suggesting cost-saving projectswhich may not be immediately apparent.

Starting with a complimentary plant“walk through” by a well-trained PCAengineer, suggestions are given which can lead to cost savings through the implementation of automated systemsand/or modifications of existing systems.

For example, PCA recently

completed a cost savings project initiallydiscovered by one of their engineers duringa plant walk-through at CertainTeed inLodi, CA, a PVC pipe manufacturer. Thecustomer had a plant-wide filtered watersystem that was running more pumps thannecessary, due to the way the piping wasconfigured. PCA worked withCertainTeed to develop a new pipingarrangement and control strategy to reducethe number of pumps that had to berunning at any given time. By usingDURApulse GS3 drive units in conjunc-tion with a new PLC and C-More HMI,PCA developed an automatic control system which cycles the supply pumpsbased upon plant demand. As a result,CertainTeed will acheive a cost savings ofover $50K a year and a return on investment of less than two years.

PCA delivers meaningful and economical solutions to its customerswhile providing the utmost in customerservice. PCA’s service area primarily coversthe Northern California valley region,however, they service clients in severalremote locations and have the ability tosupport processes via Internet and/or cellular networks. For more informationon how PCA can benefit your particularoperation, call (877) 655-8251 to set up afree consultation. You can also obtain moreinformation and fill out an RFQ form by going to our Web site at:www.pca-inc.com.

P

* Software and firmware aredownloadable for authorizedcustomers from:www.automationdirect.com

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REMOTE ACCESS AND CONTROL BUILT-INNo Additional Hardware required. The C-more RemoteAccess feature resides in all panels with Ethernet support,and requires no option modules. Access real-time dataor initiate an action on a control system from anywhere,any time. (Requires software and firmware version 2.4 or later*, and anEthernet C-more panel)

Check out the powerful yet easy-to-use features of C-moretouch panels by downloading a demo version of theconfiguration software at:http://support.automationdirect.com/demos.html

ALL C-MORE PANELS INCLUDE:• Analog resistive touch screen with unlimited touch areas• One USB A-type and one USB B-type port• Serial communications interface

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ControlLogix®CompactLogix®MicroLogix™ 1100/1400 Ethernet ENI Adapter for SLC Series FlexLogix SLC® 5/05 Ethernet™ MicroLogix™

• Modbus RTU and TCP/IP Ethernet • GE 90/30 SNPX (90/30, 90/70. Micro90, VersaMax Micro)• Omron Host Link Adapter (C200/C500), FINS Serial

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14

Press Releases

Class T fuses availableTwo series of Class T fuses have been

added to the line of circuit protectionproducts. The TJN series 300 VAC andTJS series 600 VAC fuses are extremelyfast-acting fuses in a compact, space-savingsize, making them ideal for use as the mainfuse protection for panel boards, load cen-ters, meter stacks, and AC drives. Availablein one to 600 Amp sizes, the fuses are cur-rent limiting and are designed with nointentional time delay to open quickly onoverload. Class T fuse prices start at $6.50for a single fuse, or $65 for a 10-pack.Screw and box lug-type fuses blocks forClass T fuses have also been added, startingat $8.50. To see the full line of Class T fusesand fuse blocks, visit www.automationdirect.com/fuses

Compact Pneumatic AirCylinders

The NITRA™ pneumatic productline now includes a series of compact stain-less steel, round body cylinders. The newC-series cylinders feature type 304 stainlesssteel bodies with anodized aluminum alloyheads. The type 303 stainless piston rod isequipped with Buna “N” o-ring rod sealsand sintered bronze rod bushings. Thedouble-acting cylinders are available in9/16-inch to three-inch bore sizes andstroke lengths from 0.25 inch to four inch-es. Optional clevis brackets and rod eyesare also available. Backed with a two-yearwarranty, C-series compact cylinders startat $33.

See the full line of NITRA compactpneumatic air cylinders at:www.automationdirect.com/pneumatic-cylinders-compact

Stellar full-featured soft starters

The Stellar line of soft starters nowincludes the SR44 series of solid-state softstarters to control three-phase AC induc-tion motors. The fully digital SR44 softstarters use thyristors in all three motorphases to provide controlled reduced volt-age motor control for smooth accelera-tion/deceleration and reduced mechanicalshock and starting stress.

The SR44 series features 115 or 230VAC selectable control voltage, as well aseasily and separately adjustable motor startand stop times. The AutomaticApplication Setup feature fully configures

the starter for specific applications withone entry. The advanced energy-savingOptimizing Mode improves motor efficiency and power while delivering thedemanded torque at low rpm.

These fully programmable units areequipped with six-button keypads withtwo-line, 32-character displays; program-mable I/O for remote control applicationsinclude a single digital input and two relayoutputs. An optional Modbus communi-cation card and remote keypad are alsoavailable.

Suitable for a variety of motor loads,Stellar SR44 soft starters can be used formotor reversing, with external contactors,and can be connected “in-delta”, allowingfor use of a smaller soft starter.

Stellar SR44 soft starters are UL listed, CE, REACH, and RoHS approved.Size 1 starters, with 9A to 146A currentratings, start at $769; Size 2 starters, with174A to 370A current ratings, start at $2,030.

To learn more about the full line ofStellar Soft Starters, visit:www.automationdirect.com/soft-starters

Product Snapshots


For complete information or to order online, visit:www.automationdirect.com/enclosures orwww.automationdirect.com/wiring

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NEMA 1 wall mount24 x 24 x 08”


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Choose from over 1,600Hubbell/Wiegmann enclosuresacross NEMA 1, 3S, 3R, 4, 4X, 6P,12, 4/12, and 13 ratings, all atprices well below moretraditional suppliers.

AdvancedAutomation, LLC takes baking to thenext level

dvanced Automation, LLC, inRiverdale, New Jersey, is an automation systems

manufacturing company specializing increating solutions for companies in needof more efficient automated processes.

One such need is in the bakingindustry. Food associations, such as theBritish Retail Consortium (BRC), SafeQuality Food (SQF) and the AmericanInstitute of Baking (AIB), are settingstricter regulations on tracking ingredients from their origin, to thewarehouse, to the manufacturer, andultimately to the retailer. With theseincreasing regulations and food safetyrequirements, many bakeries find it difficult to efficiently produce qualitybaked goods that are still affordable to consumers.

In late 2008, AdvancedAutomation developed the BatchProcess Analysis system (BPA©) gearedspecifically toward the baking industryto substantially improve the productionprocess. BPA assists users in followingcommon regulatory requirements and food safety practices, as well asautomatically aid in analysis of inventory and product expenditures.

BPA is a minor-ingredient batchingsystem with a very small footprint; taking no more room inside a bakerythan work benches regularly used today.The modular system is designed to notonly save space but also be time andcost-efficient.

The expandable system is equippedwith stainless steel ingredient hopperswhich are mainly controlled by twoDirectLOGIC D2-260 PLCs and anindustrial PC. User-friendly SCADAsoftware tracks and records the activitiesof daily production runs, allowing bakeries to adhere to the very strict standards set forth by the food associations. This SCADA technologyalso enables users to trace individualrecipe batches back to unique lot numbers.

By integrating major ingredients,such as flour, oil, and water, along withthe minor ingredients, bakeries can easily repeat the desired outcome everytime. The software also allows users toeasily set production schedules as well ascreate new recipes with a few simplekeystrokes.

Due to the precision of BPA, manybakeries using this system have beenpleased with increased productivity andefficiency. They are assured that information being conveyed to the enduser is accurate at all times. TheSCADA software populates all produc-tion activity which can then be easilysorted to answer various queries, allow-ing information to be traced from themanufacturer to the retailer.

Recently, Advanced Automationdemonstrated BPA at the InternationalBaking Industry Exposition in LasVegas. Companies of all sizes showedgreat interest in how BPA allows for batching and mixing of minor ingredients. Until now, it has been cost-prohibitive to replace manpowerwith automation; therefore, many facilities still perform much of the microbatching by hand. With BPA, human

hands are virtually no longer required tocomplete recipes.

Companies were further impressedthat the entirely automated microbatching system, integrated with majoringredients, has the ability to track allingredients and activities from the individual ingredients’ lot numbers tothe end user.

Marcelo Tise, president ofAdvanced Automation, stated, “We atAdvanced Automation believe in thephilosophy of ‘Eating with a smallspoon.’ We are able to offer this to ourcustomers because AutomationDirectoffers good products at fair prices alongwith superior technical support, whichwe pass on to our customers.”

To learn more about AdvancedAutomation, LLC, visit:www.advancedautomation1.comor call 973-831-2059.

16

User SolutionsImproving ingredient measuring

A

17



Student Spotlight

By Chip McDanielAutomationDirect

arry May, a student at SouthernPolytechnic State University(SPSU), contacted

AutomationDirect in April, 2010, andoutlined his goal of building a volleyballsetting and serving machine for his senior design project. Larry is active asa recreational volleyball player and is thefather and coach of a competitive highschool player. Larry is also a long timeAutomationDirect customer, and hasworked in the Automation field formany years.

He led a team including three otherstudents – Kelly Gray, Ryan Howell,and Trenton Phillips – to design andbuild a full scale working prototype ofthe “Ace Within Reach” volleyball setting and serving machine. The teamgoals were to improve on the existing“state of the art” volleyball servingmachines. Several manufacturers offersimilar machines today, but Larry and his teammates saw room forimprovement in several areas. All theexisting machines require the operatorto feed the balls manually, one at a time,into the machine, forcing the operator(usually the coach) to be at the oppositeend of the court from the player beingcoached. Larry and his team wanted tobuild a machine with a hopper to storeand feed the balls into the launcherautomatically, and to have a remotecontrol interface so that the coach canstay near the player for maximuminstructional advantage. They also envisioned a set of lights on the machine

to simulate a ‘virtual toss’, giving thehuman players an intuitive warning thatthe launch of a (potentially 80 mph)volleyball was imminent. Other criteriaincluded the ability to fit through astandard door, to roll on casters, and tohold up to 20 balls in the hopper awaiting launch.

The basic electrical design includesa CLICK PLC controlling two GSdrives (VFDs) via Modbus. The GSdrives power two small Ironhorse 3-phase motors. The ‘remote control’

consists of a C-more Micro HMImounted in a handheld enclosure, andtethered to the machine via a long serialcable. The CLICK PLC also controls aseries of lights on the front of themachine used to simulate the tossing ofthe ball into the air (prior to a serve) bya human server.(Figures 1 & 2)

The mechanical set-up uses twowheel/tire assemblies driven by theIronhorse motors – one above and onebelow the volleyball. While the twomotors work in concert to determinethe overall velocity of the launch, themachine can also impart varying degreesof top-spin to the ball by running theupper motor somewhat faster than thelower motor. Top spin and speed are theprimary variables used by volleyballplayers to vary their serves, and themachine allows a coach to vary bothspeed and top-spin from the remotecontrol. The mechanical setup alsoallows for manual adjustments to various angles of the ‘launch head’ delivery mechanism to allow a widevariety of ‘serve’ and ‘set’ simulations.Research

The team conducted a study offorces that apply to a volleyball in flightusing Computational Fluid Dynamics(CFD). The purpose of this study was topredict the path the ball would follow asit flew through the air. CFD calcula-tions were performed using theSolidWorks 2009 CAD software withFlow Simulation package. The coefficient of drag (Cd) and the coefficient of lift (Cl) are the twodimensionless parameters that need tobe determined to find the trajectory ofthe ball in flight. The following formulae show how the coefficients are determined: (Figure 3)

Automated volleyball server

L

Continued, p. 19 >>

Figure 1, CAD model of Final Design

Figure 2, Photo of prototype

Larry May

Tech Brief

18

Electrical Arcs(Part 2, Sources,Suppression & SafetyConsiderations)By Brian S. Elliott

n Part One of this article we discussed the equipment and procedures used to manage the

damaging effects of arcs in electricalequipment. In Part Two, we will discusssome of the basic methods, tools, components and circuits that should beused to operate safely around circuitswith high arc potential. Part One can befound on our web site at:http://automationnotebook.com/technology-brief.html Surge Suppressors

To a very large extent, arc suppression is accomplished by controlling high voltage transients. If asudden voltage spike initiates a sparkwithin a circuit with access to sufficientenergies, an extremely damaging arcmay result.

Recently, the application of commercially available surge suppressorshas become the accepted method forcontrolling these transients. In mostcases, a large capacity surge suppressor isapplied at the primary power connec-tion while lesser units are appliedthroughout the equipment or distribu-tion system as necessary.

In addition to limiting the initia-tion of arcs, surge suppressors are nearlymandatory for any equipment that usesmicroprocessor-based components suchas PLCs, digital displays and smart products.

Until recently, theperformance of surgesuppressors has variedamong manufacturersand even from component to compo-nent. This held true eventhough they all carry thesame ratings and were,presumably, tested usingthe same procedures.

This anomaly has been due principally to UL’s 1449 standard which specifies testing procedures for thesedevices. Previous versions of this standard left more than a few “loopholes” in testing procedures, whichallowed manufacturers a little too muchlatitude in certifying their products.

Over the past two years, UL 1449has been repeatedly updated to betterquantify the testing and make the procedures less ambiguous. The currentversion provides concise testing and procedural guidelines, leaving very littleto interpretation. This should ultimately have the effect of producing amore uniform industry standard.Crowbar Circuits

Electrically speaking, a “crowbar” isa circuit specifically designed to automatically discharge potentially hazardous voltages from a piece ofequipment when it is turned off, if thepower is disconnected or if it experiences a fault.

A great deal of electrical equipmentuses internal components that have storage potential. Even after the power is disconnected, many electrical components retain lethal electrical energies. The best example of thesecomponents is capacitors. Large capacitors retain a great deal of energyfor long periods of time - days, weeksand, in some instances, even months. Ifan unaware technician comes in contactwith these components, he may sustainserious injuries or even be killed.

The basic crowbar is a fairly simplecircuit and, in the interest of safety,should be kept that way. Figure 1 showsa typical crowbar circuit.

It consists of a holding relay thatcontrols one or more shorting relays; inthis case, a single, normally closed,three-pole unit. The shorting relays areconfigured to discharge any stored energies within the main circuit. Insome cases the stored energies may behigh enough to require some sort ofdump load, as shown in the illustration.These dump loads are typically in theform of a high wattage resistor. Crowbarcircuits are commonly designed to automatically reset, but they may alsocarry a manual reset key. (In this case,the circuit shown contains a manualreset.) Intended to add another level ofsafety to the equipment, the manualreset assures that the equipment cannotbe reenergized without a specific actionfrom a technician.The Grounding Hook

For a variety of reasons, mostextremely high voltage equipment can’trealistically utilize crowbar circuits. Inthese cases the technician must be surethat all components with storage poten-tial are manually discharged and remainin that state during the service work.This is the realm of the grounding hook,as shown in Figure 2.

These units consist of a copper barbent with a long-leg hook. The shaft isinsulated and the opposite end has twohandles with a high voltage hand guard.A plastic-coated piece of aircraft cable isconnected to a copper plate and bar.The opposite end of the cable is con-nected to a bolt-on ground clamp. Thebolt-on clamp assures that the groundconnection can’t be casually or accidentally disconnected.

Power Principles

I

Continued, p. 22>>

Figure 1, Crowbar Circuit Schematic


Where Fd = drag force (N)Fl = lift force (N)ρ = density of air @ 25° = 1 .184kg/m3V = velocity (m/s)r = volleyball radius (0.105 m)

Many CFD studies were performedto calculate the drag force (Fd) and liftforce (Fl) acting on the volleyball at various combinations of velocity, spin,and surface roughness. The CFD ‘solver’was used to determine the forces actingon the ball. These forces were thenplugged into Equations 1 and 2 and the coefficients of drag (Cd) and lift (Cl)were calculated. This figure shows a freebody diagram of forces acting on thevolleyball: (Figure 4)

The drag force acts directly

opposite to the direction of the velocityvector and the lift force, due to spin, actsperpendicular to it. Some assumptionswere made in order to allow for somewhat faster calculations and a simpler CAD model. The surface variations due to the seams wereignored, and the leather surface of thevolleyball cover was modeled with a surface roughness of 6µm and 20µm.(Figure 5)

The first flow diagram shows a stagnation point at the front of the ballwhere the air velocity is very low. On thebackside of the ball (dark blue area),some of the air actually moves in thedirection of the ball’s motion. The redareas, both above and below the ball,show that the airflow reaches a maximum velocity just above and justbelow the ball. This is due to the ballhaving the largest frontal area at thatsection perpendicular to the air flow.(Figure 6)

The second flow diagram shows theflow around a spinning volleyball.When the ball has top spin, it resists theair flowing over the top and speeds upthe flow under the ball. The red areaunder the ball is noticeably larger thanthe red area over the ball. Pressure andvelocity are inversely related, so thehigher velocity below the ball creates anarea of low pressure underneath it. Thisis the inverse of the familiar airplane

wing dynamic which creates the lowpressure area on the top of the wing.This means that the spinning ball willencounter a downward ‘lift’ force, whichwill make it drop faster than a ball thatis not spinning. This will come as nosurprise to a volleyball player who hasever faced a powerful, overhand (topspin) serve.

The team also modeled severalpressure contours, shear graphs, andflow trajectories. The value for the coefficient of drag (Cd) for all the calculations averaged 0.242. The average value for the coefficient of lift(Cl) for all calculations was 0.466.Finite Element Analysis

The team performed a FiniteElement Analysis (FEA) on a criticalshoulder bolt that holds (and helps toposition) the 140 pound launching headassembly. Due to the complex detail ofthe actual bolt used, a simplier versionwas created for FEA testing. The staticstresses on the bolt were determined tobe 65 MPa with a displacement of 0.3millimeters. The material of the bolt ismedium carbon steel with a yieldstrength of 350 MPa. Since the maximum stress on the bolt is far belowthe yield strength, this off-the-shelf bolt was deemed acceptable for the application.(Figure 7)Cost Analysis

The costs for theelectrical and mechanicalcomponents of themachine totaled less than$3000 for the completion of the proto-type, right in line with theprices charged for severalcommercially availableserving machines which donot include the multi-ballhopper or remote controlcapabilities. Of course theteam spent many hoursdesigning and building theprototype, but they believethat with certain refinements their design


Student Spotlight cont.Automated Volleyball server

Continued, p. 20>>

Continued from, p. 17 >>

Figure 4

Figure 5, 80 mph Velocity with no spin and 6um Roughness

Air Flow

20

Student Spotlight cont.Automated Volleyball server

could be manufactured at a reasonablycomparable cost - and sold at a competitive price - to the currentlyavailable machines on the market.Testing

During the initial testing phase, thevolleyballs were not launching with asmuch velocity as the team had anticipat-ed. They determined that the volleyballswere slipping against the wheels in thelaunching head. The upper wheel waslowered to add more compression to thevolleyball, thus increasing the velocity atwhich the volleyballs were beinglaunched. While this helped, themachine was still not launching balls atrealistic competition serving speeds. Theteam then wrapped the tire surfaces witha much stickier rubber layer to add extra friction, providing the desired launch speeds.Conclusions

The team was pleased with the performance of the ‘Ace Within Reach’Volleyball Serving and Setting Machine.The machine was tested by many by-standers during the testing phase andat the team’s final presentation. Therepeatability of the machine allowedtesters to improve their game by concentrating on a particular placement, speed, and spin of serve.The immediate feedback was very positive. The team has a few ideas forimprovements, and they even have alocal volleyball club who has eagerly volunteered to spend several weeks test-ing the machine and to provide detailed

feedback. After they receive feedbackfrom the volleyball club, the Ace WithinReach Team wishes to explore the possibilities of patenting and marketingthe automatic volleyball serving and setting machine.

As for Larry, this senior design project was the last step required forgraduation, and a key step towards hisnew Engineer position with Hansgrohe.Established in 1901, Hansgrohedesigns, manufactures and sells luxuryshower, bath and kitchen products. Thisinternationally recognized company isbased in Germany and has a U.S. manufacturing headquarters located in Atlanta, Georgia.


Figure 6, 60 mph Velocity with 75rad/s Top Spin and 20um Roughness

Figure 7, FEA Diagram of Simulated Shoulder Bolt

Air Flow

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IronHorse

Tech Brief cont.

22

Even though a grounding hook is ashorting device, it typically carries amaximum voltage rating. As with anyhigh voltage equipment, never exceedthe maximum voltage rating of the unit;doing so may cause serious injury ordeath. In use, grounding hooks are oftenpermanently mounted in the area wherethey are to be used. After the equipmentis disconnected from the power source,the sticks are hooked onto the appropri-ate terminals to assure that the circuit iscompletely discharged and remains inthat state.

Live TestingDespite how much technicians try

to avoid it, sometimes it is simplynecessary to troubleshoot an energizedcircuit and/or conduct live testing. Inthese situations, crowbar circuits andgrounding hooks do nothing to protect the technician.

During live testing, arc hazards areat their peak; personnel should exercisegreat care in these environments. To alarge extent, arc suppression during livetesting is done by identifying highpotential areas and avoiding anythingthat will deteriorate the stand-off effectiveness of the equipment. If the

technician inadvertently inserts a conductive tool between two highpotential terminals, it may initiate anarc that can produce serious injury oreven death.

Poor grounding exacerbates thiscondition and only serves to heightenarc hazards. In a situation where an arcforms within a properly grounded cabi-net, the hazard is safely contained anddoes little more than startle the techni-cian. However, if the cabinet isn’tgrounded, an inadvertent arc may formthrough the person standing in front ofthe box, which can instantly kill theminstantly.

Dirt build-up can significantlyreduce the stand-off voltage of any elec-trical component. As stand-off voltage isreduced, arc hazards increase. It is veryimportant to keep high voltage equip-ment clean. If a piece of equipment isparticularly dirty, it should be cleaned orreplaced before any live work is con-ducted. Properly cleaning a piece of haz-ardous electrical equipment can meanthe difference between an uneventfulafternoon and one you’ll remember forthe rest of your life.High Voltage Meters and Probes

Troubleshooting high voltageequipment is typically done with specially designed high voltage meters orordinary multimeters equipped withspecialized high voltage probes, asshown in figure 3. This particular probeis rated at 25 KV and has a 100 to 1attenuation factor. The meter is set tothe 250 volt range and the probe is connected to the input terminals. Thetechnician simply multiplies any readingby 100 to determine the circuit voltage.(Figure 3)

Following a few basic safety proce-dures makes using these probes verysafe. On the other hand, ignoring theseprocedures can cause serious bodilyharm and even death. Remember, whenworking around this type of circuitry,there is no middle ground.

When using any high voltageinstrumentation, always read andunderstand the manufacturer’s recom-

Power PrinciplesContinued from, p. 18

Figure 3, Multimeter W/ High Voltage Probe

Figure 2, Grounding Hook or “Jesus Stick”

23



mendations concerning the specificequipment.

When using high voltage probes,always connect the grounding lug to asuitable earth ground. This connectionserves an important safety function as itadds a second level of protection for thetechnician.

Similarly, never use a high voltageprobe at voltages higher than its maximum rating. During operation,one hand should be in your pocket andthe other should be used to grip thehandle. Never touch the probe in frontof the hand guard, even when the probeis not in use. Obviously, touching theforward part of the probe during usegreatly increases the technician’s chanceof electrocution. Touching the forwardpart when not in use will deposit oilsand dirt from the skin. Over time, contaminates like these can build upand affect the stand-off voltage of the probe.

Have your high voltage probes re-qualified by the factory on a regularbasis. Never use a high voltage probe ofunknown origin. If the history of theprobe is not clear, it should either besent back to the manufacturer for re-qualification or destroyed. Inspectyour high voltage probe before each use.

In any high voltage case, workbeing conducted on this type of circuitshould always be carried out by personnel who have been properlytrained for the specific equipment andsafety issues that apply to the environment. Additionally, a spottertechnician, trained in CPR, shouldalways be present when personnel areworking with potentially hazardouselectrical equipment. With the rightequipment, proper training and judicious application of safety procedures, a technician can safely workwith and around equipment that wouldotherwise be considered lethal.

User SolutionsWastewater Pumping Station

PLCs give WastewaterPumping Stations a Lift Flexible, economical PLCsprovide automatic failover,backup pump control, and remote lift station monitoring.By Jeremy Poarch, P.E., Moccasin Bend Wastewater Treatment Plant

he Moccasin Bend WastewaterTreatment Plant (WWTP) ispart of the Interceptor Sewer

System, which has served Chattanooga,Tennessee, and its surrounding metropolitan areas since it was built in 1952. The WWTP includespumping stations as well as liquid andsolids handling.

Our treatment plant receives anaverage flow of around 50 million gallons per day (gpd), and has a peaktreatment capacity of 220 million gpd.We also operate the associated sewagecollection system and remote sewage lift stations.

For the most part, gravity conveysarea wastewater from its origins to ourtreatment facility, but deep-pipe areasrequire lift stations or pumping stationsto lift the wastewater to shallower pipes.

We remotely monitor every sewerpumping station and lift station toensure normal operation. If somethingfails, we receive an alarm at our centralcontrol room at the treatment plant.Other remotely monitored informationincludes pump status (running orstopped), number of pump starts andstops, and daily pump running hours.

We recently installed new controlsat one pump station site. The new control system monitors and controlswet-well levels, and provides status andalarms over a Modbus connection. Thenew system uses two DirectLOGICDL-06 PLCs and an OptiMate HMIsold by AutomationDirect.

We designed an automatic failoversystem for this pump station site. Oneof the PLCs serves as the master; theother serves as the client, or as a redundant controller in case of a failureof the master unit.

We also recently redesigned theRemote Telemetry Units (RTUs) thatoperate and monitor our remote sewagelift stations. For the new RTUs, we also use DL-06 PLCs fromAutomationDirect.Upgrading the Pump Station Control Unit

The pump station site that weupgraded with the automatic failoversystem consists of two constant-speedpumps started across-the-line. Thepump station control unit monitors andcontrols the level of water in the storageor wet well. The controller starts andstops the pumps according to a user-defined level. It also provides high andlow level alarms, indicates whether thepump controls are in “Hand” mode or“Auto” mode, and indicates if an over-load relay has tripped.

The pump station control unit isprogrammed to alternate which pumpstarts first to distribute pump motor runtime evenly. It’s also programmed to start the second pump if the firstpump can’t provide enough effluentflow to keep the wet well within anacceptable range.

The operator enters level controlparameters via the HMI connected tothe master PLC. A Modbus connectionsends these parameters to the client (orslave) PLC. If the master unit fails,pump control is transferred to the clientPLC through a series of relays.

Pump station operation continueswithout interruption, but the operatornow needs to move the HMI cable fromthe master to the client to provide oper-ator interface to the client PLC.Attaching the HMI to the client PLCprovides a means for the operator tochange operating parameters until theissue with the master unit is resolved.

Continued, p. 27>>

T

FYI

24

ABCs of Safety Components

Safety Light CurtainsBy Lenny Filipkowski,AutomationDirect Product Manager, Industrial Components

afety light curtains are an advanced method of safeguarding personnel around

hazardous machines through the use ofphotoelectric technology and a conceptknown as Control Reliability.

Safety light curtains are a greatalternative to other traditional guardingmethods such as mechanical barriers,sliding gates and pull-back restraints;they reduce operator fatigue and offerflexibility and freedom to the operatoras well. (Figure 1)How do they work?

Safety light curtains consist of a transmitter and a receiver. A photoelectric transmitter projects anarray of synchronized, parallel infraredlight beams to a receiving unit. Whenan object breaks the beams of light, thelogic circuit in the light curtain sends asignal to the control system of themachine and stops the hazardous move-ment of the machine.(Figure 2)

The transmitter contains lightemitting diodes (LEDs) which emitpulses of invisible infrared light whenenergized by the light curtains timingand logic circuitry. These light pulsesare sequenced; one LED is

energized after another and they aremodulated or pulsed at a specific frequency. The receiving units aredesigned to detect only the specific pulses and frequency from the matchedtransmitter unit.

In order to meet the OSHA andANSI requirements for control reliabili-ty, the safety light curtains are continu-ously doing selfchecks; if the selfchecks detectany fault, thelight curtaini m m e d i a t e l ysends a stop sig-nal to themachines con-trol system. Thelight curtainthen becomeslocked in a safecondition until the faulty component isreplaced and an appropriate reset is done.

Safety light curtains also have a setof two relays in order to provide aredundant circuit. If one relay fails, thesecond will still provide the stop signal.There are two basic types of outputs forlight curtains: relays with force-guidedcontacts, and electronically cross-monitored and self checking solid-statedevices know as OSSD (Output SingleSwitching Device).In what applications are they used?

Light curtain applications are typically categorized by the type ofguarding required. Light curtains areused in guarding machines such asmechanical and hydraulic power press-es, molding presses, stamping, formingand automated assembly machinery.Safety devices are typically selected toprotect the operator’s finger or handfrom the pinch point of the machine.

If there is a perimeter or boundarydefined by a machine, robot or otherequipment, then a perimeter guard stylelight curtain may be selected.

The main difference between alight curtain designed to protect a finger

versus a hand, and one designed to protect a perimeter, is the spacing of theactual beams. A unit designed to protecta finger utilizes 14mm spacing betweeneach beam while one for hand protection is designed with 30mmbetween the beams. Perimeter stylelight curtains can have beam spacingfrom 300mm to 500mm.

How do I select the proper light curtainsystem for a given application?Several points must be addressed tomake the proper selection; some of thesefactors include:

- The size of the object or bodypart being detected or protected will determine what resolution of beam spacing is required; 14mm for finger or 30mm for hand.(Figure 3)- Determining the height and length of the area and the protectedfield to be guarded will determine the required maximum protective height of the light curtain system.- The time required for the machine or process to stop after aninterruption of the light curtain system will determine the requiredresponse time needed from the light curtain system.- The maximum distance or range needed to separate the emitter and the receiver in the application must be considered.- What type of load will the lightcurtain safety outputs control? Are they sufficient for the control

S

Continued, p. 26>>

Figure 1Figure 2, Operating Principle

Product Description AutomationDirectPrice/Part Number

JUST A FEW PRICES ON SAFETY DEVICES

AutomationDirect prices are U.S. published prices as of January 2011. Prices subject to change without notice.

Safety light curtain with 30mm resolution -24VDC, sender and receiver pair(sold separately) 0.25 to 12 meter operatingdistance, 279mm protective height,safety category 4

Safety limit switch, pull-reset action, plungeractuator, 30mm plastic body, 1/2 NPT

Safety switch, cable pull interlock, no reset,40mm plastic body

$250.00YBB-30S4-0250-G012 (sender)

$12.75AP2R11X11

$20.50SBM2K97X11

$275.00YBB-30R4-0250-G012 (receiver)

www.automationdirect.com/safety


1-800-633-0405


It could cost you a lot more in the long run. But you don’t need to overpay to get reliable, high-performancesafety devices that conform to all the latest standards. Our prices on safety switches and light curtainsmean you can do even more to protect what’s important.

Safety switches with key or hingeinterlocks, limit switches or cablepull switches give precise andquick action.• Visible operation

• Rated operational current:AC-15: 24V, 10A; 230V, 3.1A; 380V, 1.9ADC-13: 24V, 2.8A; 250V, 0.27A

• Precise operating points

• Immunity to electromagnetic disturbances

• Electrically separated contacts with positive opening operation on N.C.contacts

• Actuation speeds of 0.5 m/s (max)to 0.01 m/s (minimum)

• IEC 947-5-1, EN 60947-5-1, UL 508, CSA C22.2 No 14 approvals

Safety light curtains in finger(14mm) or hand (30mm)protection resolutions• Protective height:

14mm resolution - 142 to 1045mm30mm resolution - 279 to 1827mm

• Operating distance:14mm resolution - up to 3.5 mches30mm resolution - up to 12 mches

• Double PNP outputs

• M12 quick-disconnect models(order cable separately)

• IP65 rated; Type 4 and Category 4 PL e

Don’t let price stand in the way of making a machine or process as safe as possible

26

circuitry? This will determine the current capability required of the safety signals. Do you need semiconductor style outputs or heavy duty relay outputs for direct control of a motor starter?- What safety level or safetycontrol category does the application’s risk assessment indicate is required? Can a basic type 2 rated light curtain unit suffice or do you need the more robust type 4 units for the most protection and reliability for the application? All are points for consideration when determining the proper light curtain system.

What other functional features can safe-ty light curtains perform?

Safety light curtains can be used ina variety of different modes which canrange from providing a stop signal to amachine’s safety control circuit to moresophisticated functions such as muting,fixed blanking, floating blanking andpresence sensing device initiation.These functions can be part of the logiccircuitry in the light curtain units them-selves, or certain functions such as themuting and presence sensing device initiation can be handled by an externalsafety control relay module.What is muting?

Muting is the provisional and automatic overriding of the light curtainsafety output function during normal,uninterrupted machine cycle operation.This function allows the light grid to beinterrupted by some part of the machineor material being processed withoutstopping the operation or process.

An example of this would be a palletizing system within which the palletized product must be allowed topass through the opening protected bythe light curtain, while the entry of a person must stop the machine in a safe manner.

Muting is typically accomplishedby using an external safety control relaymodule and additional sensing devicessuch as safety limit switches or photoelectric sensors in conjunctionwith an external signaling light to showwhen the muting function is activated.What is fixed blanking and floatingblanking?

Fixed blanking is when a fixed setof adjacent light beams are set to be permanently inactive to allow productor part of the process to enter the sensing area without deactivating thelight curtain safety outputs.

Floating blanking is when a setnumber of adjacent beams are allowedto ignore the presence of an object with-in their portion of the protected field.Unlike the fixed blanking methodwhere there is a specific set of inactivebeams, floating blanking allows the setnumber of adjacent beams to “float”within the protective field. This allowsthe object to be ignored to move withinthe protected field without deactivatingthe light curtain safety outputs.

These functions are typicallydesigned into the logic in the safety lightcurtain units themselves and requiresome sort of programming or dip switch settings.

When the application allows forthe use of safety light curtains, the

functions and benefits allow theprotected machine to run more safelyand more productively than many otherprotection devices. The most important,consideration when choosing a brand oflight curtains is to make certain theymeet all requirements of the relevantsafety standards such as EN/ISO13849-1:2008 (former EN 954-1), andEN/IEC 61496-1:2004/-2:2006 typerequirements. Also, it is important toverify these have been tested and certified by an independent, recognizedthird party such as TUV in order tomake sure they are compliant to the relevant standards for safety light curtains.


FYIABCs of Safety Components

Figure 3, Resolution of the access control barrier or light curtain

“A bank is a place that will lend youmoney if you can prove that you don'tneed it. "

– Bob Hope

We designed the automatic failoverto operate in case of PLC failure, whichwould normally result in an after-hourscall to an electrical technician. Thefailover function allows the station tofunction normally until repairs can bemade during regular work hours.

An output on the master PLC isheld energized by an “always-on” bit inthe PLC. If the master PLC stops operating, the output de-energizes aseries of relays. The appropriate relaycontacts direct the outputs of each PLCto the appropriate control relay to provide failover operation.

The two main control PLCs shareoperational parameters, basically levelsettings. The master PLC also retrievespower quality data from a power qualityanalysis meter through a Modbus connection. The PLC then sends allappropriate data to a data logging unit,also connected via Modbus.Establishing the Modbus communica-tions between the non-PLC devices wasthe most challenging part of this proj-ect.

In this particular pump station, aseries of dry contacts provide alarms andpump status indications to an RTU.One pair of contacts is used for eachfunction. The RTU, in turn, sends thisstatus and alarm information to thetreatment plant central control room viaa licensed radio system.Upgrading the RTUs

We’ve considered replacing ourRTU systems for several years. We chosethe AutomationDirect PLCs as the heartof our new RTUs because we couldobtain what we needed quickly and fora lower cost than from other suppliers.Because we could have hardware in ourhands in a matter of days after the order,we were able to develop these systemsquickly. Also, the PLCs we chose provided us with additional pump control options.

The new RTUs operate and monitor our remote sewage lift stationsthrough a cellular connection. At thecentral control room, an OPC server

connection provides information to aPC-based HMI. The connectionbetween the control room and eachRTU is via a cellular network.

When we installed the first of thenew RTUs, we found it extremely convenient that those of us authorizedto work with the PLC logic could accessthe unit remotely. The operator incharge of monitoring the stations hascalled me many times in the evening oron weekends asking me to take a look atthe site.

I can connect to the PLC from myhome, and see how the site is perform-ing. I can assess the conditions andadvise whether the situation is “normal”or needs attention from maintenance oroperations. I can even determinewhether an issue had arisen here at theplant with the PC, based on what Icould see from the PLC.

There is a communication issuewith the RTUs that we’re working toresolve. The software driver residing onthe PC can handle some delay betweenthe data-request message and theresponse to that message. However, thecommunication delays we’re experienc-ing over the cellular-based Internet connection have forced us to look foralternate connection methods.

Our local power distributor is implementing a fiber-optic-basedInternet service, which we feel holds thekey to resolving this issue. We are currently evaluating sites to find goodcandidates for a pilot project using thishigher speed connection.

We’ve installed 16 RTUs so far, and many of these units have been retrofitted into enclosures that used to contain older radio-based

RTU equipment.System Upgrades Worth the Effort

The new pump station control unithas proved to be more reliable than theoriginal control system. We don’t havespecific records of how many times theoperations staff was dispatched to thesite in the past, or how many times elec-trical maintenance was needed afterhours. However, I have noticed that thefrequency of issues at the site hasdecreased dramatically.

We attribute the drop in after-hours calls to the increased reliability of the new control unit andredundant PLC. Although we’ve sthoroughly tested it, we haven’t yet hada situation that required the use of theautomatic failover function. If it saves usonly once, it was worth the effort.

Purchase price was one of the mainconsiderations for the RTU systemPLCs. The hardware is modular, so wedon't have to buy more than we need.We’ve installed 16 systems so far, and wecalculate that our choice in PLCs is saving us around $200 per site. Whenyou consider that we have more than 80remote sites, the savings can add up quickly.

User Solutions cont.Automation Notebook Winter 2011 Issue Nineteen



Control Cabinet

“Time is what we want most, but whatwe use worst."

– William Penn

Wastewater Pumping Station

Best power to dollar ratiohelps you do moreUse the technology built into the Productivity3000programmable controller to make your job easier. Its speedand power make the P3-550 CPU an unbeatable value at$599.00. The system consistently executes 3 kbytes ofBoolean logic and 1k of I/O in less than 650 microseconds.And power? This CPU does the work of multiple pieces ofhardware compared to other controllers. With its sevenbuilt-in communication ports, you get:

• Plug-and-play USB or Ethernet programming and monitoring• USB local I/O expansion port (no local I/O master module needed)• Ethernet remote I/O expansion port (no remote I/O master

module needed) • High-speed Ethernet port for HMI (up to 32 C-more panels), controllers,

and enterprise system communications (no Ethernet module needed)• Two serial ports for peripheral device interface or controller

networking (no serial communcation or ASCII module needed)• USB port for data logging to removable drive and project transfer

The 50Mb memory supports large programs, completewith tag name database and program documentationstored onboard. And with a huge (100,000+) I/O capacity,the Productivity3000 can handle just about any systemyou need.

AutomationDirectlaunches 3D CADcatalog on TracePartsWeb site

utomationDirect now has 3DCAD models available throughTraceParts, an online provider

of 2D drawings and 3D models.Customers can find the 3D models bygoing to www.tracepartsonline.net andselecting the “AutomationDirect” listing.There are also direct links to the modelsfrom the item level pages on theAutomationDirect Web store. We willcontinue to maintain our libraries of 2DCAD drawings on our store site as wellfor the foreseeable future.

The TraceParts Online CAD portalis freely available to millions of CADusers worldwide, offering a convenientway to download 3D models in the mostpopular file formats. This initial launchincludes 128 part numbers coveringCLICK and Productivity3000 PLCs, C-More micro operator panels, PSP24power supplies, and GH Series motorcontactors and overloads.

We will continue to add 3D modelson a monthly basis as new files are completed. Visit:www.tracepartsonline.net to view thecomplete list of models, and begindownloading at will!

AutomationDirectachieves 10th straightyear of #1 service

For the 10th year in a row,AutomationDirect has been voted topsin service by readers of Control Designmagazine. Their Readers Choice Awardssurvey polls machine builders and system integrators to rate their experiences with automation vendors. In50-odd hardware and software categories, survey participants name thecompanies that provide them the besttechnology value for the products withwhich they have experience. Once theychoose the best providers, participantsrate service and support they receivefrom them. In 2010, AutomationDirectreceived the highest service rating of anyvendor for the following product categories: PLCs, PLC programmingsoftware and Operator InterfaceTerminals. We also received the highestservice score across all vendors. Our

dedicated Technical Support team continues to put our customers first, andit shows – thank you all for your vote of confidence!

Atlanta BusinessChronicle ranksAutomationDirect asone of the “BestPlaces to Work” in Atlanta

AutomationDirect was named oneof Atlanta's Best Places to Work in 2010by the Atlanta Business Chronicle.

Employees voted the company tothe number two position in the medium-size company category by completing a 37-question online survey.The survey focused on specific categoriesrelating to a company's workplace culture. Things considered included:team effectiveness, trust in senior leaders,feeling valued, manager effectiveness,compensation and benefits. Companieswere then ranked and finalists chosen ineach size category based on their overallcomposite score. Winners were chosenbased strictly on the results of the survey.According to Anne Reich of the AtlantaBusiness Chronicle, winners are, inessence, chosen by the employees themselves. In 2010, approximately 500companies were nominated.

Expressing gratitude, company captain Tim Hohmann says, "Thisaward is the best compliment to ourcompany and management team that Icould ask for. We feel if teamers lovewhat they do, they'll naturally take careof customers with dedication and enthusiasm. And that does prove truebased on the many customer surveys we do."

Business NotesAutomation Notebook Winter 2011 Issue Nineteen

A


“By all means marry; if you get a goodwife, you'll be happy; if you get a badone, you'll become a philosopher.”

– Socrates

www.automationdirect.com/c-more-micro or www.c-moremicro.com

We squeezed the features of our popular TFT 6-inch C-more Microinto a 4-inch package for even more value! Take advantage of theclear and colorful graphics on the TFT color touch screen to createa vibrant and intuitive operator interface. Five programmablefunction keys give you lots of flexibility.FREE programming software offers the choice of using manybuilt-in objects, such as buttons, bar graphs and data entrykeypads. Or import your own custom graphics, and save to librariesfor use in multiple projects. Alarm control, recipes and a built-inproject simulator are time-saving tools for more complexapplications. All these features at a competitive price, in a ruggedand reliable package, give you a sweet HMI for even the smallestcontrol system. * 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).

Also Available

Get a big bang for your buck

Popular protocols/devices supported

* All AutomationDirect programmable controllers* Modbus® RTU* Allen-Bradley® DF1 half/full duplex, PLC-5®

DF1 and DH485* Siemens PPI* GE Fanuc 90™ -70 and 90-30 SNPX* Omron Host Link and FINS serial* Mitsubishi MELSEC®

Go online for complete list 3-inch touch andnon-touch panels

6-inch STN and TFT touch panels

Optional plug-and-play keypad bezelsfor 3- and 6-inch models

• Mounts in standard 1/4 DIN cutout• 32k Color TFT touch screen display• LED backlight• 320 x 240 resolution• 3.2 MB memory• Mounting variations for key orientation• Five durable function keys with LED indicators• Standard Type B USB programming port• 15-pin serial communications port• Enhanced objects and graphics• Up to 999 screens (dependent on complexity)• Recipes• Built-in project simulator• UL, cUL, CE, NEMA4 and 4X indoor ratings


1-800-633-0405


BrainTeasers

Packing PuzzlesPack the given number of each

shape in the given box size. The shapesmay be rotated and reflected, but should not overlap. Each puzzle has a unique solution.

Each shape consists of a group ofsmall squares; the size of those squares isthe reference for the given box size.

Go online for a helpful MS Exceltemplate - it won’t solve the puzzles for

you - but it’s more convenient than cuttingout paper-dolls!http://www.automationnotebook.com/PuzzleTemplate.zip

Our thanks to Erich Freidman forthis issue’s puzzles. Packing Puzzles ©Erich Friedman 2009Check out more of Erich’s Puzzles here:http://www2.stetson.edu/~efriedma/puzzle.html

31


The Break RoomBrainTeasers

Please visit www.automationnotebook.com to find the answers to these puzzles.

Example: Solution:

Pack 4 copies of in a 4x7 box

Note: This simple example does have multiple solutions.

1. Pack 5 copies of in a 6x7 box




5. Pack 6 copies of in a 5x9 box 6. Pack 6 copies of in a 7x8 box






The NITRA family now includes rugged directionalsolenoid valves and air prep components:

• Solenoid valves with 24 VDC or 120 VAC control voltages,starting at $16.75

• Regulators in ranges of 20-130 psi or 7-60 psistart at $17.00

• Mist-type air lubricators start at $12.25• Air filters start at $11.25

www.automationdirect.com/pneumatic-parts

AutomationDirectNITRA

MSC

All prices are U.S. published prices. Many other part numbers are available from all vendors. Items are closest equivalents; some minor differences may exist.Automationdirect prices are from October 2010 Price List. MSC prices are from www.mscdirect.com 9/6/10. McMaster-Carr prices are from www.mcmaster.com 9/6/10.

Grainger prices are from www.grainger.com 9/6/10. Prices subject to change without notice.

Grainger

Directional Solenoid Valve5-port, 4-way, 2-position, 1/4” NPT, 24 VDC, single solenoid

$26.75AVS-5312-24D

$29.00AFR-3233

$84.8184470475

$115.4742007401

$60.786124K513

$72.767390K17

McMaster-Carr

$90.153JCN6

$104.204ZK92

Product Description

Combination Filter/Regulator1/4” NPT, gauge, mounting bracket

CHECK OUT OUR PRICES ON PNEUMATICS

Get best prices on ALL the components you need to complete a pneumatic control system!

• Stainless Steel cylinders and switches• Polyurethane and nylon tubing• Most popular fittings• Meter-in, -out, and inline flow control valves• Stop, check and manual hand valves

Other NITRA components available in the most popularstyles and sizes


1-800-633-0405


Directionalsolenoid

valvesand manifolds

Filters

Regulators

Lubricators

Filter/regulator combos

Relief valves

Documents

Automation Notebook: Online Technical Magazine Issue 19 · Bryant Manual Motor Controllers starting at $21.50 • Lockout / Tagout capability • 30, 40 and 60A up to 600 VAC