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PLCS hUMAN MAChINE INTERFACES TEMPERATURE CONTROLS SOLID STATE RELAYS
06 08 10 14
SChNEIDER ELECTRIC
Are your systems and suppliers flexible enough to help you stay ahead?
Irrespective of your companys output, manufacturing consumer goods, intermediate goods, machines and control panels, taking advantage of opportunities quickly is vital if you want to stay ahead of your competitors.
Company environments have to be dynamic due to the pressure of continued performance improvements to stay ahead of the competition and the need for profitability within the modern manufacturing environments. Its a fact that those companies that can embrace change, outperform those that dont. The rigid automation systems built in the past with closed networks and single PLCs make it hard to adapt systems, these restrictions in themselves can become a barrier to quick and efficient change, when companies really need to adapt. Basic requirements for todays factory automation systems and components involve: Flexible and interchangeable modular functions to enable a range or line extension and adaptations Simple to use and easy to maintain Cost effective optimum performance Smart plug and play with embedded communication and diagnostics Compact high functionality in minimum space Open protocols enabling simple communication with other devices, decentralised or remote access for monitoring and diagnostics
The challenge for todays engineers is not finding the products, its finding a supplier who can and will help you propose the optimum solution for your application. Ask the question, is my supplier proposing a solution based on my needs, or does it lock me into a specific protocol or approach? that may benefit the supplier more than you and your company. RS and Schneider Electric support the move to open architectures and controller inside products with technical and applications support to help you achieve the most appropriate and cost effective solution be it a simple or complex system.
WELCOME
CONTENTS
Whats inside this issue...
04 06 08 10 13 14 15 16
Welcome to the November 08 edition of the new RS Automation publication. We hope you enjoy the magazine!
PLCs and control technologies are the brains or centre of any system and selecting the right one can be a real challenge. RS is here to help you choose Whether its a brand new process, or replacing an existing out-dated controller, choosing the right programmable logic controller (PLC) platform for your application can be daunting. With a range of solutions from simple logic control to compact, or advanced PLCs, the solution is simple if you ask yourself the right questions. Find out what you need to ask on page 4 & 5. Perhaps your process requires temperature control. Whether that is a basic On Off control process or a more sophisticated proportional, integral, derivative (PID) controller RS can help. This edition contains a very useful section on improving your temperature control process as well as some of the language of temperature control. With a range of automation products from well respected and high quality manufactures, RS is your link to finding the right solution for your automation applications. Visit www.rsaustralia.com and find out more about the products we can provide to help you.
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All products in this issue are sold subject to the terms & conditions of sale set out in the current RS 2008 catalogue. Prices exclude GST, which will be charged at the relevant rate. All prices valid until 31st March 2009. Free delivery anywhere in Australia for all orders over $100 exclusive of GST.
Logo!
S7-200
S7-300C
Zelio
Twido
Zen
CP1L CP1A, 2A
CJ1M CQM1/1H
XC Series
As a starting point you should only consider a logic controller for slower processes with an I/O requirement of less than 20 I/O. Beyond that level of I/O a compact or intermediate PLC provides a better solution with increased processing speed available. For large I/O applications with networking and remote I/O requirements an advanced PLC would be the best choice. The amount of memory needed for the program is more difficult to size, but modern PLC processing units feature memory capacities suitable for the majority of application and have the option of expanding the program memory if required.
COMPACT PLCS
Fx2N PLC
Top of the Mitsubishi FX family of PLCs, offering extremely fast program execution, accepts up to eight special function modules and provides maximum flexibility and control for all your factory automation applications.
100% backward compatible with older FX units Choice of 6 I/O sizes, expendable up to 256 I/O 0.08s basic instruction speed 8K step RAM, expandable up to 16K with EEPROM 125 applied instructions, 3072 auxiliary relays, 256 timers, 235 counters and 8000 data registers
Fx FAMILY MODULES
DIN rail mounting modules which attach directly to the right-hand end of the previous unit, block or module via a short integral lead.
FX2N-16EX-ES/UL: 16 I/P Digital expansion module FXON-3A: 2 I/P, 1 O/P Module FX2N-HC: High speed counter module GX Developer FX: Windows based software for FX series PLCs
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320-8976 8 I/P 8 relay O/P 320-8982 16 I/P 16 relay O/P 320-9042 8 I/P 8 transistor O/P 320-9058 8 I/P 8 transistor O/P
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488-6729 S7-222 8 I/P 6 transistor O/P 488-6634 S7-222 8 I/P 6 relay O/P
(85-246Vac)
434-1844 2 channel RTD temperature 468-5807 Ethernet communication 488-6454 Micro/WIN V4.0 software
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444-4404 6 I/P 4 relay O/P (100-240Vac) 528-8609 6 I/P 4 relay O/P (24Vdc) 444-4482 16 I/P extension module 528-8687 8 channel analogue
I/P module and cable
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6 AUTOMATION NOVEMbER 08 - MARCh 09
ADVANCED PLCs
Q SERIES CPUs & ExTENSION bASE UNITS
Cost effective, powerful processors, ideal for local and remote machine control, remote I/O networking of conveyors, pump control and many other PLC applications in food and beverage processes.
Easy to set up and expand a system Fast processing speeds and large memory capacity Uses Windows based GX software
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455-6793 CPU 8k step 455-6816 CPU 14k step 455-6737 Main base unit 8 I/O slots 455-6822 QX80 16 channel digital I/P module 455-6939 QY10 16 channel relay O/P module 399-7812 GX developer software 455-6670 QC30R2 programming cable
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Level 1 2MB RAM CPU Level 2 4MB RAM CPU 6 slot backplain rack 16 channel digital I/P module 16 channel digital O/P module 4 channel analogue I/P module Unity Pro (small) development software
Peripheral port
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S7-312C:10 I/P 6 digital O/P (24Vdc) S7-313C:24 I/P 16 digital O/P (24Vdc) S7-313C-2 DP: 24 I/P 16 digital O/P (24Vdc) expansion module module
453-2517 S7-300 series 16 I/P 469-1694 S7-300 series 8 relay O/P 539-1755 Step 7 Lite software V3.0
510-1394 CPU 11 160 I/O, 10 module capability 512-5845 CPU 12 320 I/O, 10 module capability 512-5889 16 channel digital I/O module 512-5895 8 relay O/P module 510-1495 8 NPN transistor O/P module 510-1467 4 I/P & 2 O/P analogue module 536-5548 CX-One programming software
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456-5028 Text operator terminal 2 lines (5Vdc) 456-5034 Text operator terminal 2 lines (24Vdc) 399-6241 E series programming software
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NT33 TOUCh-SCREEN TERMINALS
Versatile, compact units offering powerful, free programming functionality in a space saving compact design that lets you create your own function keys wherever you want them on your screen and at the same time make use of text in multiple languages.
FREE Windows based programming via the Download Centre at www.europe.omron.com 4.1 monochrome STN LCD display with green backlight Support for floating point data Save recipe data in non-volatile memory 120KB screen data capacity Printer connection NT3S-ST126BE RS-232 port NT3S-ST123BE RS-232/485/422 ports Real time clock Historical alarms
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617-3340 Monochrome display 617-3334 Colour display 617-3378 WinCC flexible compact software
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3 level backlight brightness adjustment Supports 16 languages NS5: 5.7 256 colour STN LCD display (320 x 240dpi resolution) 20MB memory NS8: 8 256 colour TFT LCD display (640 x 480dpi resolution) 60MB memory
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617-2808 XBT GT2220 5.7 colour screen 617-2791 XBT GT2120 5.7 monochrome screen 617-2892 Programming cable 2m 617-2864 Programming software
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TEMPERATURE CONTROL
PID Control
Process temperature reaches set-point quickly and stabilises
The simplest form of temperature control is provided by basic thermostats and temperature controllers. When the process is cooler than the set-point, the heater is turned on at maximum power. The process temperature then rises approaching the set-point. Once the process achieves the set-point temperature the heater is switched off completely. Due to the thermal capacity of the heating element the process temperature overshoots the set-point until natural cooling has an effect. This is very noticeable in a process involving a large thermal mass. As the above graph shows, these fluctuations continue throughout the heating process. The turn-on and off temperatures differ by a small amount, known as the hysteresis, to prevent rapid switching of the heater when the temperature is near the set-point.
In simple terms, PID control can be thought of as : Proportional How hard you drive the output Integral How often you drive the output Derivative Drives the output with respect to the current rate of temperature change A proportional control method can be used on its own and is an improvement compared to basic on-off control, reducing fluctuation. Proportional control varies the amount of energy supplied to the heating element in direct proportion to the difference between the current process temperature and the required set-point. PID control combines the improvement that proportional control offers with an integral and derivative function. The integral function prevents the initial overshoot, while the derivative function eliminates the temperature instability once the set-point is achieved. PID control delivers the benefit of allowing the process temperature to be reached very quickly without overshoot or continual fluctuation.
Advantages of On-Off Control: Simple and cost effective method of temperature control Requires virtually no setup Disadvantages of On-Off Control: Overshoot during initial heating cycle Imprecise control - process temperature fluctuates around set-point Inefficient un-required heating energy is wasted
Advantages of PID Control: Improved control when compared to either proportional or On-Off Elimination of overshoot and temperature error Compensates for process thermal dynamics autotune feature Only the energy required to reach and maintain the process temperature is used Disadvantages of PID Control: Can be more expensive than a basic On-Off controller
TEMPERATURE CONTROL
6100+ SERIES TEMPERATURE/PROCESS CONTROLLERS
These instruments are microprocessor based indicators, single loop controllers and profilers capable of measuring, displaying or controlling process variables such as temperature, pressure, flow and level from a variety of inputs.
116 DIN 48 x 48mm mounting Full PID control with Auto Tuning Broken sensor detection and loop-failure alarm Remote set-point and digital input option Supports thermocouple, RTD and DC linear inputs IP66 front panel protection
Page 1,576
Relay O/P 100-240Vac Relay O/P 24-48Vac/dc DC SSR O/P 24-48Vac/dc PSI-CON configuration software
Reverse action
This is the most common mode of operation. When the process temperature is below the set-point the controller output drives the heating element.
Direct action
Page 1,578
611-8343 611-8371
$771.00 $850.00
This mode of operation is normally associated with a cooling process, as the output is only operated when the process temperature is equal too or higher than the set-point.
Dead band
Dead band or dead zone control allows a neutral zone to be defined around the setpoint, for example, a deferential of +/- 5C around a set-point of 50C. If the process temperature increased above 55C an output would drive a cooling function e.g. a fan. If the process temperature fell below 45C another output would drive a heating function e.g. heater element or operate a valve and ignitor for a gas burner.
Series 3300 1/32DIN 1 x SPST relay, 1 x SSR output Series 3300 1/32DIN 1 x SPCO relay, 1 x SSR output Series 9500P 1/16DIN 2 x SPST, 1 x SSR output RS-232 communication board RS-485 communication board
TEMPERATURE CONTROL
DUAL DIGIT TEMPERATURE CONTROLLER
A sophisticated, autotuning D330 DIN PID controller with selectable thermocouple, RTD or analogue inputs and up to three outputs, with relay or SSR ouput options.
Large dual 4-digit LED display of set point and process value Can be configured as 1 On/Off or PID control and up to two alarm outputs, or as 2 On/Off or PID control (heat/cool) plus one alarm output Inputs: Type J, K, T, R, S, C, E, B, N, U, W and Platinel thermocouples, PT100 2/3 wire, -5 to 56mV, 0 to 10V, 0 to 20mA
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85-270Vac SSR output 85-270Vac relay output 24Vac/dc SSR output 24Vac/dc relay output
85-270Vac relay output 85-270Vac SSR output 24Vac/dc relay output 24Vac/dc SSR output
Monitoring Products:
610-8829 610-8813
K8AB K8AB-TH12S
Temperature relay, 0 - 399C/F, Thermocouple and PT100 input Temperature relay, 0 - 1,700C/F (minimum setting 10C), Thermocouple input
$177.00 $177.00
Single-Loop Control:
611-7750 611-7744
K3MA-L-C K3MA-L-C
$338.00 $338.00
611-9885 611-9879
E5CSV E5CSV
Temperature controller, 12Vdc pulse output Temperature controller, SPST relay output
$303.00 $303.00
Page 1,581
E5CN-R2MT E5AN-R3MT
Temperature controller, DIN48 x 48mm, relay output Temperature controller, DIN96 x 96mm, relay output
K3HB-HTA K33-CPA
Digital panel meter, Thermocouple and PT100 inputs Option board (Slot B), 1 relay (PASS) SPDT and 12Vdc 80mA sensor power supply Option board (Slot C), 4 relays (HH/H/L/LL) SPNO for each relay Option board (Slot D), NPN open collector event input card 5 points M3 terminal block
E5EN-Q3HMT Temperature controller, DIN48 x 96mm, 12Vdc output, heater burnout alarm E5EN-R3HMT Temperature controller, DIN48 x 96mm, relay output, heater burnout alarm
K34-C2 K35-1
A choice of control voltages are available; low voltage DC control typically 3-32Vdc, or high voltage AC control typically 90-280 Vac. The control voltage is considered similar to a relay coil voltage.
heating Applications
Heating applications have repeated frequent load cycling as the elements are turned on and off to maintain the required temperature. Heating elements are predominately resistive, so surge currents at switch-on are low. This makes Zero Voltage turn on SSRs ideal for heating applications. Choosing the suitable solid-state relay is easy to do if you consider the following: Full Load current of the elements Line voltage being switched Available heat sink - oversize where possible, or select a device with integral heat sink Ambient temperature - in heating applications elevated temperatures are common and you may need to de-rate the SSR Therefore, to maximize the life expectancy of the SSR, the selected device will have a continuous rating of at least 2x the full-load current, Zero Voltage turn-on and a voltage rating higher than the supply voltage.
AUTOMATION PRODUCTS
NON-ILLUMINATED FLUSh MOUNTING MOMENTRY PUShbUTTON SWITChES
50% cheaper than an actuator and contact block, plus easier to fit.
Rated to IP66 for harsh environments 22.5mm diameter hole mounting Temperature range -25C to +70C
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ThREE PhASE SSR
The D53TP series provide three phase switching in a compact puck style body using SCR outputs for maximum reliability, with a variety of load types such as motors, heating elements and transformers.
LED status indication Line voltage 48-530Vac Screw terminals Matching heatsink available
228-1986 228-1992
$36.70 $40.10
25A 3-32Vdc control 50A 3-32Vdc control 25A 90-280Vac control 50A 90-280Vac control MS3 DIN rail mount heatsink
535-6364 535-6386
$49.50 $54.90
hANDTOOLS
Innovation
KNIPEX pioneers ideas in pliers. KNIPEX innovations offer futureoriented solutions and sets the standard for easy, effective and reliable products. Development work relies on intensive sharing of experience with users while incorporating the most modern design technology available.
Ergonomics
Particular attention is paid to the ergonomic design in the production of KNIPEX pliers. Products are designed to reduce the effort required to operate and ensuring a handle which is ideally suited to the moving hand to ensure minimum fatigue and maximum safety at work.
158-5726 Super Knips style 0 158-5748 Super Knips style 2 158-5760 Super Knips style 6 248-1811 ESD Super Knips style 6 248-1827 ESD Super Knips style 0 158-5732 Electronics Super Knips inox 158-5776 Electronics Super Knips SP tool 287-8653 ESD Super Knips medium 287-8669 ESD Super Knips hard 187-7340 Electronics pliers pointed head 187-7407 ESD Electronics pliers round head 187-8315 Electronics pliers round head 187-8343 Electronics pliers round head
$70.10 $71.90 $72.20 $80.30 $79.50 $52.90 $53.90 $56.50 $58.40 $83.10 $82.40 $82.80 $78.90
287-8681 ESD Electronics pliers round head 600-7697 Flat Nose pliers 600-8101 Flat Nose ESD pliers 600-8117 Snipe Nose pliers 600-8123 Snipe Nose ESD pliers 600-8145 Round Nose ESD pliers 158-5647 Box joint pliers, flat wide jaws 158-5653 Box joint pliers, half-round jaws 187-7362 ESD Electronics pliers flat 524-3505 Diagonal cutters 600-8224 Diagonal ESD cutters 187-7390 ESD Electronics pliers end cut
$87.30 $94.80 $98.40 $94.80 $98.40 $98.40 $69.30 $69.30 $66.40 $116.00 $120.00 $99.10