automation notebook magazine issue 23, summer 2012 from

Automatlon IEBO_

rnrlud Focus Industrial Strength Enclosure Heater and Enclosure Lighting Options

User Solutions Biodiesel Fuel Gets a Boost from Automation

Technology Brief Important Considerations for Replacing and Sizing AC Motors

Copyright, 2012. AutomationDirect.com, All rights reserved.

Complete PLC starting at $69Mighty as a stand-alone unit, orexpand to 142 total I/O

Product Description AutomationDirectCLICK

Price/Part Number

CHECK OUT JUST A FEW PRICES ON CLICK

AutomationDirect prices are U.S. published prices as of April 2012. Prices subject to change without notice.

PLC CPU with 8 DC inputs / 6 DC outputs (sinking),two communication ports

Auxiliary power supply (0.5A), 100-240 VAC input,24 VDC 0.5A output

AC input module, eight 100-120 VAC points

$69.00C0-00DD1-D

$29.00C0-00AC

$40.00C0-08NA

PLC CPU with 4 DC inputs / 4 DC outputs (sinking),2 analog inputs / 2 analog outputs, threecommunication ports, real-time clock

$129.00C0-02DD1-D

With CLICK PLCs, you get a lot of application controlin a small package. The new Standard CPUs featurethe discrete I/O configurations of the Basic CPUs, plusbattery-backed memory, real-time clock and a thirdcommunication port.

• Eleven stand-alone DIN-rail mountable DC-poweredCPU combinations including:

- 8 DC In / 6 DC Out (sinking) -Basic and Standard- 8 DC In / 6 DC Out (sourcing) - Basic and Standard- 8 DC In / 6 Relay Out -Basic and Standard- 8 AC In / 6 Relay Out -Basic and Standard- 4 DC In / 4 DC Out (sinking), 2 analog in, 2 analog out

(current / voltage selectable)- 4 DC In / 4 DC Out (sourcing), 2 analog in, 2 analog out

(current / voltage selectable)- 4 DC In / 4 Relay Out, 2 analog in, 2 analog out

(current / voltage selectable)

• Built-in communication ports(two in Basic CPUs, three in Standard and Analog CPUs)

• Battery-backed memory and real-time clock(in Standard and Analog CPUs)

• Removable terminal blocks for easy wiring• Eleven stackable, discrete I/O option modules• Program AND documentation stored in CPU• Supported by FREE, high-feature programming software www.automationdirect.com

1-800-633-0405

Go online or call to get complete information,request your free catalog, or place an order.http://www.automationdirect.com/click-plc or

www.clickplcs.com

Download the free programming software now andsee how easy automation can be.


http://www.automationdirect.com

http://www.automationdirect.com/click-plc

http://www.clickplcs.com

3

Automation Notebook Summer 2012 Issue Twenty Three

www.automationnotebook.com

Contributors Editor’s Note Table of ContentsWhat a year we are having at

AutomationDirect! Several productadditions have been launched so far;many of which you will read about inthis issue of NOTEBOOK. Plus, thereare many more heading down the pipe. We often share news of our award-winning customer service and our toprankings on various reader polls.Perhaps one of our greatest achievements is being ranked by ourco-workers. This past April, the Atlanta Journal-Constitution namedAutomationDirect as the Top Mid-sizeWorkplace in the Metro Atlanta area.Our employees voted the company tothe top position in the medium-sizecompany category by completing anonline survey which covered areas suchas company direction, workplaceconditions, execution, management,career, and pay and benefits. Also, ourcompany captain Tim Hohmann wasamong the heads of three companiesreceiving the Leadership award, honor-ing those who lead by example.

In this issue of NOTEBOOK, wefocus our Student Spotlight on a groupat San Diego State University. Theyrecently participated in a theatre technology expo, where they demonstrated how PLCs can work intheatre and on stage. Our User Solutionstory details how products fromAutomationDirect have helped aCalifornia company simplify the production of biodiesel while loweringproduction costs as well. Plus, be sureto read the Product Manager’s Cornerto learn about the latest and greatestour Productivity3000 controller has to offer.

There’s a lot more, including theever-popular Breakroom. Test your witsto see if you can solve the mind teasers.But, most of all, sit back, relax, andturn the page…

TJ JohnsCoordinating [email protected]

New Product Focus 4Industrial Strength Enclosure Heaterand Enclosure Lighting Options

Product Snapshots 6Jefferson Electric Buck-BoostTransformers, Stainless Steel ProximitySensors, Metal Guard Foot Switches,Pneumatic Solenoid Valve Cables andConnectors, Bryant Industrial GradeDuplex Receptacles and WatertightWiring Devices and Accessories, FieldWireable Connectors and T-couplersavailable, Air Pilot and Manual ControlValves, Multi-Function DigitalTimer/Counter/Tachometers,Productivity3000 High-Speed CounterInput and Pulse Output Modules,Stainless Steel and Air DifferentialPressure Transmitters, WERMA audibleand visual signal devices, Bryant cord grips

Feature Story 10Cloud Computing in the Forecast

System Integrator Corner 15CH2M Hill joins AutomationDirect’sSIDirect team

User Solutions 16Biodiesel Fuel Gets a Boost fromAutomation

Product Manager’s Corner 20Set Your PAC in Motion

Tech Brief 22Important Considerations for Replacingand Sizing AC Motors

Student Spotlight 23PLC Training at the United StatesInstitute for Theatre Technology AnnualConference and Stage Expo

Business Notes 25Goings-on in the industry

Break Room 27BrainTeasers

Publisher Tina Gable

Managing Editor Joan Welty

Coordinating Editor TJ Johns

Design Manager Justin Stegall

Contributing WritersJoe Kimbrell

Christine LesherChip McDaniel

Jeff PayneLoren Schrieber

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 2012. 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/free-stuff.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


mailto:[email protected]

http://www.automationnotebook.com


http://www.automationnotebook.com/

New Product Focus

4

Industrial StrengthEnclosure Heater and EnclosureLighting Options

TEGO enclosure heaters, thermostats, hygrostats andhygrotherms protect against

condensation while providing the greatest possible air circulation.

Touch-safe convection heaters aredesigned to utilize natural convection,resulting in a circulating current ofwarm air while minimizing surface temperatures on the accessible side

surfaces of the housing. The compact,DIN rail-mountable units are availablein 12 to 30V AC/DC and 120 to 140VAC/DC models and with heating capacities ranging from 10W to 150W(depending on model). Touch-safe convection heaters start at $24.25.

Fan heaters with an operating voltage range of 100 to 120VAC areavailable in screw-mount and DIN rail-mountable versions as well as panel-mount and foot-mount models.Designed with high-performance axialfans, the units provide forced air

circulation to prevent the formation of condensation and ensure evenly distributed air temperatures. Screw-mount and DIN rail-mount units haveheating capacities of 150W to 650W(depending on model) while panel-mount and foot-mount versions have950W or 1200W heating capacities.Panel-mount and foot-mount modelsare designed with integrated adjustable

thermostats and built-in overheat protection. Fan heater prices start at$86.75.

DIN rail-mountable enclosurethermostats have also been added.Tamperproof styles available in normally-open and normally-closedmodels feature fixed set points and areavailable in single and dual versions.Adjustable thermostats available includesingle units in normally-open and normally-closed models as well as dualunits containing one normally-open andone normally-closed thermostat withseparate color-coded adjustable temperature controls. Thermostat pricesstart at $12.

Electronic hygrostats sense relativehumidity and activate the enclosureheater at a setpoint to help prevent theformation of condensation within theenclosure. Available in two models(120VAC and 230 VAC), the DIN rail-mountable electronic hygrostats feature adjustable relative humidity setpoints (40% to 90% RH), highswitching capacity and a visual functiondisplay. Hygrostat prices start at $55.

Electronic hygrotherms provide efficient temperature and humidity control. With a temperature settingrange of 32℉ to 140℉ and a humidityrange of 50% to 90%, the unit isdesigned with a high switching capacityand optical function display. Thehygrotherm senses the ambient temper-ature and relative air humidity. The unitthen turns a connected device either onor off if either the temperature is belowor the humidity is above the set point.Hygrotherms are priced at $82.75.

LED lights suitable for panels andenclosures have also been added.Available with either On/Off switch ormotion sensor, and in magnet-mountand screw-mount versions, the powerfuloutput allows up to 10 lights to be con-nected together. LED light prices start at$67.50.

See the full line of Enclosureheaters at:www.automationdirect.com/enclosure-climate-control.

What’s New

S


http://www.automationdirect.com/enclosure-climate-control

www.automationdirect.com/c-more-microor www.c-moremicro.com

We squeezed the features of our popular TFT 6-inch C-more Micro intoa 4-inch package for even more value! Take advantage of the clear andcolorful graphics on the TFT color touch screen to create a vibrantand intuitive operator interface. Five programmable function keysgive you lots of flexibility.FREE programming software offers the choice of using many built-inobjects, such as buttons, bar graphs and data entry keypads. Or importyour own custom graphics, and save to libraries for use in multipleprojects. Alarm control, recipes and a built-in project simulator aretime-saving tools for more complex applications. All these featuresat a competitive price, in a rugged and reliable package, give you asweet HMI for even the smallest control 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 SNPX* Omron Host Link and FINS serial* Mitsubishi MELSEC®

Go online for complete list3-inch touch andnon-touch panels

6-inch STN and TFT touch panels

Optional plug-and-playkeypad bezels for 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

www.automationdirect.com

1-800-633-0405

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


http://www.automationdirect.com/c-more-micro

http://www.c-moremicro.com


Product Snapshots

6

Jefferson Electric Buck-Boost Transformers

Buck-boost transformers fromJefferson Electric are designed to maximize the performance and life ofelectrical equipment, such as air conditioners, heating elements, 277-voltlighting systems, and in motors applications. Also called an isolation transformer, typical use is to power loads with specific voltage requirementswhich differ from the available line voltage.

Jefferson Electric 60Hz single-phase buck-boost transformers, with50VA to 2kVA ratings, are encapsulatedwith electrical-grade resin, featuringhigh-quality electrical steel cores. TheNEMA 3R-rated enclosures are heat-cured with an ASA-61 gray powdercoat finish and have slotted mountingholes for quick and easy mounting.

A buck-boost transformer can havetwo main applications. When connectedas an auto-transformer, you can buck(lower) or boost (raise) available linevoltage anywhere from five to 20 percent. When used as an isolationtransformer, it can be used to step-downsupply power to low voltage circuits atthe nameplate rating listed.

Buck-boost transformers start at$53 and are UL approved and arebacked by a 10-year limited warranty.

Learn more at:www.automationdirect.com/buck-boost-transformers.

Stainless Steel Proximity Sensors

Our line of round bodied stainlesssteel inductive proximity sensors nowincludes 3-wire NPN output versions in8, 12, 18 and 30mm models; also neware unshielded 3-wire 12, 18 and 30mmmodels. All models have a full 316Lstainless steel barrel and sensing facethat provides extreme durability inharsh environments, with standardquick-disconnect cable connections.Starting at $45, all units are cULus, CEand RoHS rated and have a limited life-time warranty. See the full proximitysensor line at:www.automationdirect.com/proximity

Metal Guard Foot Switches

Metal guard foot switches havebeen added to our line of product offerings. These switches, in single anddouble units, are designed with die-castaluminum foot cover guards and heavy-duty ABS plastic bases and pedals.

Ideal for machines such as shearingand spinning machines, lathes, wrap-ping machines and riveting machinesand presses, the foot switches are available in three operational formats:safety anti-trip, free moving and freemoving maintained. The IP65 –ratedfoot switches feature two normally-openand two normally-closed contacts withsnap action or slow action options available. Metal guard foot switch pricesstart at $59 and are backed by a one-year warranty. Learn more at:www.automationdirect.com/foot-switches

Pneumatic Solenoid ValveCables and Connectors

The pneumatics product line now includes several high-quality connectors and cables designed for mostpopular pneumatic solenoid air valvesand sensors.

Three-wire connector cables areavailable in five pin spacing formats(8mm to 18mm); a four-wire transmitter cable is also available in the8mm format. Connector styles includeDIN 43650 standard forms A, B and C;two DIN style industrial forms (B andC) are also offered. The 24V or 110VAC/DC models feature built-in surgesuppression and yellow LED indicatorand are rated for connecting with electronics. The 230V AC/DC modelsare rated for straight-wired products.

Select connectors are field-wireable; all connector styles are available with three and five-meter PVCjacketed cables. Because the connectorsare not polarity sensitive, users followsolenoid, sensor, or other devices wiringdiagrams for proper connection.

Press Releases


http://www.automationdirect.com/

http://www.automationdirect.com/proximity

http://www.automationdirect.com/foot-switches

7



Cables and connectors for solenoidvalves start at $4.75. For more productdetails, visit:www.automationdirect.com/solenoid-valve-cables

Bryant Industrial GradeDuplex Receptacles andWatertight Wiring Devicesand Accessories

The Bryant wiring devices line nowincludes extra-heavy-duty industrialgrade duplex receptacles and watertightwiring devices.

Bryant industrial grade duplexstraight blade receptacles feature a full-face, wrap around design molded ofhigh-impact chemical-resistant nylon.Available in 15A and 20A versions, thereceptacles are designed with a one-piece copper alloy grounding systemwith integral solid brass grounding contacts. Eight wiring pockets provideconvenient feed-through back wiringand clamp-type terminals with brass terminal screws, and accept up to #10wire; easy-access break-off tabs supporttwo-circuit wiring. Available in gray orcorrosion-resistant high-visibility yellownylon, receptacles also feature a circuitID marking area for clear identificationof circuits. Industrial grade duplexreceptacles start at $9.25.

Two-pole and three-pole water-tight plugs and connectors have alsobeen added. Recommended wheremoisture exists or casual submersion ispossible, these devices are constructedwith high-visibility yellow double-insulated thermoplastic elastomer hous-ings. Individual neoprene bushings provide a watertight seal. Rugged PBTinteriors provide excellent resistance tomoisture and temperature. A tongue

and groove plug-to-connector designprovides optimum protection in wetand damp locations. The 15A and 20Aconnectors accept multiple cord diame-ters from #18/3 to #10/3; 30A modelsaccept #8/4 cord. Watertight plugs andconnectors start at $14.

Weather protective accessories,starting at $3.25, have also been added, including NEMA 1 non-conductive, impact-resistant thermo-plastic elastomer portable outlet boxes, dual-receptacle covers and blank boxcover plates. Learn more about theBryant wiring devices atwww.automationdirect.com/watertight-wiring-devices

Field Wireable Connectorsand T-couplers available

Field-wireable M8 and M12 con-nectors and T-couplers (T-splitters) areideal for making patch cables in customlengths from existing cables or bulkwire. Connectors are available in axial(straight) or right angle configurationsand three, four, or five-pole versions. T-couplers are available in four and five-pole versions and come in four models:three models split Male M12 to twoFemale M12 connectors and one modelsplits one Male M12 to two Female M8connectors. Connector prices start at$6.75. Learn more at:www.automationdirect.com/idc-connector

Air Pilot and ManualControl Valves

The NITRA® line of pneumaticproducts has been extended to includeair pilot valves, foot pedal valves, andmanual control valves.

The AVS-5 series now includes

single and double-pilot directional control air pilot valves, offering springreturn or center closed operation. All arebody ported five-port (four-way) spoolvalves and are available in 1/8” to ½”NPT port sizes with flow coefficientsfrom 0.67 to 2.79. AVS-5 series air pilotvalves start at $14.

NITRA CVS series directionalcontrol foot pedal valves are five-port(four-way) spool valves designed fornon-electrical operator control applications. Available in momentary orlatching operation models, foot pedalvalves feature a ¼” NPT port with aflow coefficient of 0.80. CVS foot pedalvalves start at $25.50. The full line ofNITRA air pilot valves can be seen at:www.automationdirect.com/air-pilot-valves

Manual valves in toggle-style handlever, push-pull, and rotary-style handlever models have also been added.Constructed with aluminum alloy bodies, available port sizes are 1/8” to½” NPT with flow coefficients from0.78 to 5.29. Starting at $14, models areavailable in two or three-positiondetented styles. The new NITRA manual valves can be seen by visiting:www.automationdirect.com/manual-air-valves.

Multi-Function Digital Timer/Counter/Tachometers

The new CTT series multi-func-tion devices are easily configured foroperation as a digital counter, timer,combination timer/counter, ortachometer. The units offer selectablecounting speeds up to 10,000 cycles per

Continued, p. 8>>



http://www.automationdirect.com/solenoid-valve-cables

http://www.automationdirect.com/watertight-wiring-devices

http://www.automationdirect.com/idc-connector

http://www.automationdirect.com/air-pilot-valves

http://www.automationdirect.com/manual-air-valves

Product Snapshots

8

second. Available in standard 1/16 DINsize, the series comes in 24 VDC and100-240 VAC powered versions.Multiple transistor and relay output versions are available.

The devices feature double-line,six-digit, two-color LCD displays forcounter, timer, or tachometer presentvalues, setting values and menu parameters during setup. Parameters canbe easily set using externally accessibleDIP switches or the lockable keypad.Additional individual indicators are provided for inputs, outputs and functions.

CTT units are equipped with twooutputs; Output 1 is a single-pole single-throw relay and NPN transistorthat operate concurrently. Output 2 canbe ordered as either a single-pole double-throw relay, or NPN transistor.

Priced at $69, CTT Series devicesaccept voltage and non-voltage inputsfrom a wide variety of NPN, PNP, ordry contact sensors. Learn more aboutCTT Series devices at:www.automationdirect.com/Counter-Timer-Tach.

Productivity3000 High-Speed Counter Input andPulse Output Modules

The Productivity3000 programma-ble automation controller line includesthree new modules.

The P3-HSO high-speed outputmodule ($349) supports Pulse/Direction, Up/Down and Quadraturepulse outputs on each of two independent output channels. It hasboth line driver and open drain outputs

and features six general purpose high-speed inputs and four general purpose outputs. The module is fitted with sixfault status LEDs, six input LEDs, andeight output status LEDs. Simple move,velocity move, and additional high-levelinstructions make it easy to implementapplication motion profiles.

The P3-HSI high-speed inputmodule ($329) has both differential andsingle ended inputs. This moduleaccepts Pulse/Direction and Quadraturesignals on each of the two independentinput channels. Equipped with fourfault status LEDs, eight input LEDs,and four output status LEDs, it alsoprovides four general purpose high-speed inputs and four general purpose5-24 VDC 0.5 amp outputs.

The P3-16TD3P DC output module ($151) is a sinking/sourcingprotected output module which provides 16 12-24 VDC sinking orsourcing outputs with four internallyconnected commons. LED indicatorssignify missing external 24 VDC, openload, over temperature, and over loadcurrent conditions.

Modules are UL and CE approvedand backed with a two-year warranty.See the full Productivity3000 line atwww.automationdirect.com/productivity3000.

Stainless Steel and Air Differential Pressure Transmitters

The ProSense SPT25 pressuretransmitter series is engineered to meetmany industrial, commercial and OEMpressure measurement applications.Compatible with many different mediasensing applications, the all stainlesssteel welded thin film sensing element

provides very fast response time. With apressure sensing range from vacuum to5,000 psi, transmitters are designed toresist vibration, shock and EMI/RFIwhile providing high accuracy over awide compensated temperature range.Models feature a ¼-inch NPT malethreaded process connection and areavailable with linear outputs of 4-20 mAor 0-10VDC and with electrical connections of either a DIN 175301-803C L-connector or a two-meter integral shielded cable. SPT25series pressure transmitter prices start at $109.

The ProSense DPTA series differential air pressure transmitters areprecision engineered for accurate lowdifferential pressure measurement of airand non-condensing, non-corrosivegases. Transmitters are equipped with anultra-thin single silicon crystaldiaphragm capacitive sensor to provideinherent repeatability and stability.These transmitters are designed withbrass barbed pressure ports, removableterminal blocks and a rugged ABS hous-ing for DIN rail or panel mounting. Theseries is available in ranges from 0.1inches to 25 inches water column tomeasure positive, negative, and bi-directional pressures, with the abilitywithstand 15 psi overpressure withoutdamage or calibration shift. Backed witha three-year warranty, prices start at$105. For more information onProSense pressure transmitters, visit:www.automationdirect.com/pressure-sensors.

Press ReleasesContinued from, p. 7


http://www.automationdirect.com/counter-timer-tach

http://www.automationdirect.com/productivity3000

http://www.automationdirect.com/pressure-sensors

9



WERMA audible and visualsignal devices

WERMA audible buzzers and optical beacon lights are designed for useon control panels and enclosures.

WERMA 22.5mm panel-mountelectrical buzzers are available in 14models and in 115V AC/DC and 24VAC/DC styles. Constructed of polycarbonate /ABS housing material,the electrical buzzers are designed tomount in a 22.5mm hole. Buzzers areavailable in continuous and pulse tonemodels with volume ranges of 80 to 100decibels; certain models provide eightselectable tones and feature adjustablevolume levels up to 100 decibels at onemeter. Each buzzer is equipped withsimple connector-plug connections.

Additional 22.5mm panel-mountcontinuous-tone (80 dB at one-meter)electrical buzzers feature LED indicatorswith either red or yellow lenses. The 150Series buzzer is available in 24 VDC and115 VAC models; the 450 Series buzzerwith acknowledgement functionrequires 24 VDC and is silenced by simply pressing the front of the indicator. Prices for 22.5 mm panel-mount electrical buzzers start at $29.

LED and incandescent beaconlights have also been added and areavailable in red, green, yellow, clear andblue. Two-wire, high-intensity LED29mm diameter beacons are available inpanel-mount styles, or M20 threadedbase versions for use with limit andcable-operated switches. Available in 24VDC and 115 VAC styles, prices for29mm beacons start at $55.50.

WERMA 57/58 mm diameter bea-con lights are available in permanentincandescent, LED and Xenon flashingmodels. Designed for use in 22.5 mmstandard control panel holes, the

beacons provide 360-degree visibility.Incandescent models require a maxi-mum 48V while LED and Xenon flash-ing models require either 24 VDC or115 VAC power. Designed with 6.3mm x 0.8 mm spade connectors, thebeacons are finger safe when used withinsulated spades. Prices start at $28.50.

Also added are 75mm diameterbeacon lights in blinking, rotating orpermanent LED models, as well as flash-ing Xenon and permanent incandescentmodels. LED and Xenon styles are available in 24 V AC/DC and 115 VACmodels while incandescent modelsrequire up to 250V (depending on bulbselection). Beacons feature high-impactpolycarbonate lenses available in red,green, yellow, clear or blue.Incandescent bulbs are sold separately.Prices for 75mm beacons start at $37.

See the full line of WERMA audible buzzers and optical beaconlights and accessories at:www.automationdirect.com/signal-devices.

Bryant cord grips

The Bryant wiring devices line nowincludes wire and cable grips, strainreliefs, support grips, and pull grips.

Bryant cord strain relief grips areused to connect cable enclosures andindustrial equipment and prevent cablepullout at the point of termination.When used in conjunction with bus drop support grips and safetysprings, the devices are an integral partof an overall cord support and strainrelief system.

Deluxe strain relief grips, suitablefor indoor and outdoor applications, arecorrosion resistant and feature endlessstainless steel wire mesh weave to provide easy installation and arc-of-bend

control; grips are designed with aluminum fittings and oil-tight, water-tight and dust-tight neoprene bushings.Starting at $29, deluxe cord strain reliefgrips accommodate a cable diameterrange of 0.187” to 1.687”.

Dust-tight strain reliefs aredesigned for use in bus drop grip systems, motor connections, panelboards and internal wiring of machines.The dust-tight grippers are constructedof galvanized steel mesh, and are offeredin models for use with cable diametersfrom 0.32” to 1.70”. Designed for indoor use only, the dust-tight gripsstart at $9.

Standard duty support grips, forindoor and outdoor use, are applied tovertical or horizontal runs of cable orservice lines to support dead weight.Designed with strand equalizers to rein-force gripping strength and distributeloads equally, standard duty gripsaccommodate 0.54” to 1.74” cablediameter ranges. Standard duty supportgrips start at $15.50.

Light duty bus drop support grips,for indoor use, support flexible cablewhere it connects electrical equipmentto bus duct. The single variable weavegrips are made of galvanized steel foradditional holding power in abrasiveenvironments and attach to 0.24” to1.25” cable diameter ranges. Bus dropsupport cable grips start at $7.

Galvanized steel low-tensionpulling grips are ideal for use in utilitywork, industrial and commercial build-ing service lines, and undergroundtransmission line stringing. The singleweave variable mesh provides uniformpositive grip power while protectinglines from abrasion. The reusable gripsare fitted with a flexible eye which easilyattaches to pulling line snake or fishtape. Starting at $15, low-tensionpulling grips are available for 0.25” to1.74” cable diameters. Learn more aboutthe Bryant wiring cord grips atwww.automationdirect.comstrain-relief-grips.



http://www.automationdirect.com/signal-devices

http://www.automationdirect.com/strain-relief-grips

Feature Story

10

Cloud Computing

Cloud Computing in the ForecastCloud-based applicationspromise to deliver benefitsfor industrial applications,but implementation challenges exist.By Christine Lesher

loud computing is becomingincreasingly attractive forbusiness and personal

applications where its low cost solutionsand fast deployment help companiesand individuals save time and money.

Many people already use the cloudfor document management, data backup, Web mail, and music and videostorage. These applications are free orvery inexpensive, and reliable enoughfor the most part.

More businesses are taking advantage of cloud-based applicationsto help streamline their operations andreduce costs. As reported in theIndustrial Networking Q2 2012 coverstory “The Cloud is Coming,” a recentreport from The Economist IntelligenceUnit and IBM indicates that 90 percentof America corporations plan to use thecloud in their organization by 2015.

Businesses are using the cloud insimilar ways to individuals for data storage, Web mail and large data filetransfers like software downloads. Somecompanies have gone to the next step byoutsourcing entire functions, switchingto a software-as-a-service (SaaS) modelin which the cloud provider hosts anapplication accessed via a thin client ora Web browser. An example of this is acustomer relationship managementservice, such as Salesforce.com, in whichusers pay a monthly fee for the service,as an alternative to in-house softwareand databases. Real Benefits

It’s easy to be skeptical about thebenefits of cloud computing as many

have become immune to the hype aboutthe latest technologies. However, thecloud really does provide significantbenefits, especially in terms of costreductions when compared with in-house systems.

For example, data storage andbackup have traditionally been therealm of in-house IT departments thatinstall and manage the software, servers,etc. However, many businesses arechoosing cloud providers for data stor-age because economies of scale result inextremely low fees. For this and otherapplications, using a cloud providereliminates or dramatically reduces labor,purchasing and maintenance costs asso-ciated with implementing an in-housesolution.

Another important benefit tocloud computing is faster deploymentand upgrades. Since the cloud providerhandles all the deployment andupgrades, a SaaS application can bedeployed in as little as an hour or two,

instead of the weeks or even monthsrequired for an in-house solution.

The cloud, as a remote application,often simplifies and expands remotedata access. No longer do companiesneed to maintain a virtual private network (VPN) to enable access to applications. The Cloud for IndustrialManufacturing

While cloud computing isn’t ascommon in the industrial automationworld, its benefits are making it moreattractive for industrial applications.However, simply duplicating the sametype of applications and architectureused for other businesses isn’t the bestway to introduce cloud computing toindustrial manufacturing, due to theunique needs of the automation sector.

Industrial applications rely heavilyon real-time data, and at present it’s difficult to see industrial users depend-ing on cloud computing to deliver thistype of information. Nevertheless,

C

Why Use the Cloud Instead of In-House IT?1. Add new resources on demand when and if needed

2. No need to purchase redundant hardware and software licenses

3. No need to set up disaster recovery sites that may not be used

4. Faster deployment of new applications

5. Higher speed downloads

6. Provides huge amounts of storage capacity that can be purchased incrementally

7. More paths for uploads and access purchased incrementally

8. 24/7 maintenance services

9. More comprehensive security

Table 1: Cloud vs. In-House IT

Cloud Concerns1. Data security

2. Dependence on cloud provider

3. Internet connectivity issues

4. Lack of existing regulations

Table 2: Cloud Concerns


industrial manufacturers will most likely follow the lead of other businessesand use the cloud for tasks that supportmanufacturing, particularly data storageand remote access.

In general, there are two methodsfor performing manufacturing relatedtasks. Using the first and currently mostcommon method, the cloud will host aservice provided to the manufacturer bya system integrator or an automationvendor. This service will then be sold to the manufacturer, typically on amonthly subscription basis. The secondmethod involves manufacturers, usinghardware and other associated infra-structure provided by others, to runtheir own applications in the cloud.

Regardless of the method selected,two-way access to the automation

controllers isn’t typically provided.However, this too is changing as systemintegrators are working with OEMs to design cloud-based access andcontrol systems with automated two-way communications.

For example, in the event of analarm, the controller could send an alertto a user via the cloud. The user couldacknowledge the alarm, and then send acommand to the controller to correctthe issue.

This two-way access via the cloudwill be a significant change from today’smodels. In some instances, the cloudwould become part of the critical pathbetween the end user making a decisionand the control system receiving it. Inthe same way when control systems firstmoved to non-proprietary networks,

these developments are almost certain toinvolve some controversy.Considerations for Cloud Computing

Many industrial companies’ datacontains intellectual property they wishto protect from their competitors.Although cloud providers offer manysecurity features and devices, it can stillseem risky to send data into the cloudwhere others may be able to access it.

Reliability is also a concern for industrial manufacturers who have traditionally only used in-house systemsfor their production and manufacturingprocesses. They may fear relying onInternet connectivity and outside service suppliers over whom they haveno direct control.


11www.automationnotebook.com

Continued, p. 12>>

Image 1: ARC, page 4. Cloud-based can be purchased as hosting services for a user application or as software as a service. Diagram supplied by ARC Advisory Group.



Feature Story Cont.Cloud Computing

12

While data stored in the cloud isprotected by a variety of security measures, storing data outside the plantdoes create a new type of vulnerability.The cloud provider should have muchstronger security and encryption inplace, with 24/7 support to stop unauthorized access, than a typical in-house IT department. Data security isthe meat and potatoes of cloudproviders, giving them an incentive tobe informed of the latest securitythreats, as well as to implement the latest security measures.

However, the collective data in thecloud is much more extensive and valuable than the data in a single industrial company, which makes it amore attractive target to hackers.Applications and data may faceincreased risk from network threats thatwere previously defended against at theperimeter of the organization’s intranet,as well as from new threats that targetexposed interfaces.

A configuration or software errorcould accidentally allow access to organizational data and resources toother subscribers. An attacker could alsopose as a subscriber to exploit vulnerabilities from within the cloudenvironment to gain unauthorizedaccess. Botnets have also been used tolaunch a denial of service attack againstthe infrastructure of a cloud provider.

Having to share an infrastructurewith unknown outside parties can be amajor drawback for some applications;it demands a high level of assurance ofthe strength of the security mechanismsused by the cloud provider.

Users must also have confidence inthe long-term stability of the cloudprovider because of the near totaldependency on the selected cloudprovider, and this dependency increaseswith the length of time the provider is used.

For example, a company may use acloud provider for manufacturing datastorage. The selected provider wouldcontrol the data and be free to raise

prices at any time. If the manufacturerdecided to switch to another provider, itwould require cooperation from thecloud provider to transfer the data.

While regulations exist in the U.S.and other countries that require transferof money and/or data from one providerto another for the financial services andtelecommunications industries, no suchregulations exist for the cloud yet. Onthe other hand, it would be unlikely forfuture regulations not to implementsimilar requirements.

Outside of data security, thebiggest concern among industrial usersis the dependency on an Internet connection to access cloud data.Alternate access paths are typically provided by cloud providers, but usersmay see internal networks as more reliable than any practical number ofInternet connections.Making the Leap

While remote access is the mostobvious draw for the cloud in terms offunctionality, asset management is veryappealing and seems to be particularlywell suited to the cloud. Improving assetutilization is important to manufactur-ers, but in-house deployment requireslarge investments in software, servers,networks—as well as IT and assetmanagement experts.

Asset management through acloud-based model could facilitate vir-tually instant deployment with very lowup-front costs. A manufacturer wouldonly have to provide a high-speed two-way data connection to the control andinformation system, and then the vendor could immediately begin collecting and analyzing data.

After analyzing the data, the ven-dor could provide specific recommenda-tions for improving asset utilization. Fora monthly fee on a relatively short-termbasis, this application would minimizesome of the concerns about beinglocked into a vendor or contract.

Manufacturing stands to benefitfrom the cloud, and new applicationsare being developed on a continuingbasis. However, it’s unlikely cloud computing will be used for real-timecontrol any time in the foreseeable future.

Instead, the cloud is more likely toprovide services associated with manufacturing, such as remote accessand data storage.

As with any new technology orapplication, concerns exists in regards toreliability and control. Standards andregulations need to be established, andmost likely will be as the market grows.As the technology matures for theindustrial automation market, it’s agood bet that cloud use will becomemore widespread among manufacturerswho will benefit from its cost savingsand faster deployment.

Continued from, p. 11

“Give a man a fish and he eats for aday. Teach him how to fish and youget rid of him all weekend. ”

– Zenna Schaffer


The DL205 micromodular PLC is an industry workhorse, time-testedin some of the toughest industrial settings. Installed in thousandsof applications, its wide range of I/O and communication optionsensure you’ve got the tools you need to do the job. And our directprices, 30-day money-back guarantee and FREE award-winningtechnical support are all standard features that make that job alittle easier!

DISCRETE: Choose from 25 discretemodules that support AC, DC and relay I/Otypes. All modules have removableterminal blocks for easy wiring and modulereplacement. Our newest DC output moduleperforms electronic short circuit protection.

ANALOG: 19 analog modules offerinterfaces to current and voltage signals,as well as thermocouples and RTDs.Connect devices such as processtransmitters, proportional valves andAC drives.

COMMUNICATIONS: The DL205 series makesEthernet communications easy andinexpensive. Get fast peer-to-peer accessto HMI, other PLCs and PCs on the factoryfloor at one of the lowest costs per nodein the industry.

Test-drive the software for FREE! Our fully functional PC-DS100 programmingpackage can create and download programs to all our DirectLOGIC PLCs(max 100 words runtime; unlimited programming package PC-DSOFT5 is $395 ).

DirectLOGICDL205

Allen-BradleyCompactLogixPLC modules

* All prices are U.S. published prices. Prices and specifications may vary by dealer and configuration. AutomationDirect pricesare from April 2012 Price List. Allen-Bradley prices are based on www.rockwellautomation.com/en/e-tools 2/20/12.

Discrete Modules $282.80$240.38$314.11$289.87

$135.00$91.00$99.00$100.00

CHECK OUT OUR PRICES ON PLC MODULES

Ethernet interface

Analog Modules

Communications

AC 16-pt. inputDC 16-pt. inputDC 16-pt. outputIsol. relay 8-pt. out

4-channel input (current)4-channel thermocouple in8-channel output (voltage)

$201.00$301.00$271.00

$301.00

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HIGH-SPEED/MOTION: Counter modulesinclude a simple counting input moduleor a high-speed input/pulse outputmodule for interfacing to stepper or servodrives. Using our SureServo or SureStepmotion systems with the DL205 gives youa very cost-effective motion control system.

High-speedcounting

Download the software online at:http://support.automationdirect.com/downloads.html


http://www.rockwellautomation.com/en/e-tools

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

www.automationdirect.com/c-more

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 an Ethernet C-more panel)

C-more touch panels in 6" to 15" sizes are a practical wayto give plant personnel easy access to controls and data. Check out the powerful yet easy-to-use configurationsoftware by downloading a demo version 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

FULL-FEATURED MODELS ADD:• 10/100Base-T Ethernet communications• CompactFlash slot for data logging

C-more touch panel line-up:6-inch STNgrayscale

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8-inch TFT10-inch TFT 12-inch TFT

15-inch TFT

Starting at:$432

Starting at:$540

$1,081 $1,727 $2,051 $2,484

CONNECT TO CONTROLLERS WITH DRIVERS FOR:• All AutomationDirect PLCs/PACs

• Allen-Bradley - ControlLogix®, CompactLogix®,MicroLogix™ 1100/1400 Ethernet,ENI Adapter for SLC Series, FlexLogix, SLC® 5/05 Ethernet™, MicroLogix™

• Modbus RTU and TCP/IP Ethernet• GE SNPX• Omron Host Link Adapter (C200/C500),

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Our C-more remote HMI application,for iPad®, iPhone® or iPod touch®, isavailable on the App Store for $4.99.It provides remote access and controlto a C-more panel for mobile userswho have a wi-fi or cellular connection.


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System Integrator CornerTurnkey SolutionsCH2M Hill joinsAutomationDirect’sSIDirect team

ince its beginning in 1946,CH2M HILL has become aglobal leader by providing full-

service consulting and design, as well asdesign-build and operations and pro-gram management in over 80 countries.

Headquartered in Englewood,Colorado, CH2M HILL was foundedon the principle of meeting high-endchallenges and creating technical inno-vations. CH2M HILL provides turnkeysolutions designing, engineering, andbuilding projects, while meeting andexceeding goals of both public and pri-vate clients. CH2M HILL delivers inno-vative, practical, sustainable solutionswhich help clients develop and manageinfrastructure and facilities that improveefficiency, safety, and quality of life.

With deep industry knowledge anda breadth of resources across various dis-ciplines, they develop solutions whichtake advantage of technologies, recom-mended practices, and knowledgedrawn from the various industries theyserve to help clients quickly respond tochallenges at every stage of a project.

CH2M HILL provides completeproject services through various businessgroups, from architecture, engineering,

and construction to program and facili-ties management. They also providecomplete system integration fromBatch, Continuous and DiscreteControls to Business Planning andLogistics. As a full service provider, theirclients receive a complete solution wheresimplicity trumps complexity, resultingin profitability.

Their control and systems integra-tion specialists offer complete solutionsfor projects in existing facilities, as wellas in new facilities in all design/ construction phases.

As systems integration (SI) special-ists, CH2M Hill provides full-servicedesign, programming and commission-ing for any size project including:

• Programmable Logic Controllers

• SCADA Software / Systems• Remote Monitoring and

Internet Access Portals• Facility Controls• Manufacturing Process

Monitoring

A winery enlisted CH2M HILL’sdesign, construction, and system integration services to improve produc-tion at their fermentation, storage andbottling facility. The new system included the use of DL205 PLCs andseveral operator interface terminals configured for alarming and local setpoint adjustment. A SCADA systemwas also included to provide reporting,trending and historical data collectionand retrieval.

On another occasion, CH2MHILL integrated new dissolved oxygen(DO) meters and variable frequencyblower drives into a wastewater plantwith PID control and SCADA interface.A DirectLOGIC 405 PLC providedcontrol, with an Ethernet interface. Thenew system allowed much better controlof the DO levels at the plant, reducingthe risk of discharging dirty water intothe Columbia River. They also provideda remote access solution so operatorscould always see what was going on,since the plant is not staffed full time.

With complete project lifecyclecapabilities, CH2M HILL covers everyphase of any project including the plan, design, build, upgrade, expansion, renovation, and operation of infrastruc-ture and facilities. Then, when assetsreach the end of their useful life, CH2M HILL can decommission,decontaminate, and demolish them,while restoring the environment for newuses. With their years of expertise,CH2M HILL helps increase efficiency,improve speed to market, resolve stakeholder concerns, streamline complex project delivery issues, successfully implement first-generationtechnologies, maximize scope withincost constraints, and create lasting value.

Learn how CH2M HILL can helpwith your next project:

Website: www.ch2m.comContact: Justin ColtonPhone: 503-736-4084E-mail: [email protected]


S



http://www.ch2m.com

mailto:[email protected]

Biodiesel Fuel Gets a Boost fromAutomationSystems produce biodieselfor a total cost as low as 67cents per gallon, turningwaste into profit

magine if restaurants and othercommercial food enterprises couldturn used kitchen oil into fuel

instead of simply disposing of it. Thenimagine if they could do that in an eco-nomic and automated way for a fractionof the cost of the petroleum diesel that itreplaces. Now add in the ability toprocess other oils extracted from crops,and to generate valuable byproductssuch as animal feed.

At Springboard Biodiesel(www.springboarddiesel.com), our customers are doing just that by usingour BioPro™ biodiesel processors toconvert organic oils into ASTM-gradebiodiesel that works with any dieselengine.

We’ve designed our small-scaleprocessor series of machines, named theBioPro, to do the majority of the workthrough an automated process thatrequires almost no user interaction. Nomore turning valves, metering in chem-icals and carefully monitoring themachine. Instead, users simply add therequired ingredients and press a button.All over the world, BioPros are recyclingwaste oils into low-cost clean fuel. TheFlorida National Guard producesbiodiesel from used vegetable oil to fuelstate maintenance vehicles at the CampBlanding Joint Training Center inStarke, Florida. Remarkably, the Guardhas been able to convert its waste cook-ing oil to biodiesel for a total cost of 67cents per gallon, when all savings fromwaste disposal are taken into account.

Daphne Utilities in Alabama created its award-winning cookinggrease recycling program with a BioPro190, in the process reducing sewer spillscaused by grease plugs that posed a risk

to nearby Mobile Bay. The public dropsoff used cooking oil at stations through-out the city, and the utility processes theoil into fuel.

With a mere $12,000 start-up cost,Daphne Utilities saves approximately$10,000 a year by creating biodieselfrom used oil for about a dollar a gallon,not to mention the significant savingsfrom a 40 percent reduction in spillsand avoided waste oil disposal costs.

Nothing goes to waste, as the utility uses the biodiesel to run emergency power generators, and as afuel additive to increase lubricity. It evenuses the glycerin generated during thecooking oil processing to make soapsthat are used to educate the public about the program.

The Colusa Indian CommunityCouncil uses its BioPro 380 to makebiodiesel from a combination ofreclaimed cooking oil from the council'scasino restaurants, and from saffloweroil extracted from sunflowers grown bythe tribe. When making biodiesel fromsunflower screenings mixed withalmond shells at a 90-10 blend, theremaining meal can be sold for approximately $200 per ton for use as aprotein-rich feed for livestock. Thecouncil calculates its total cost to makebiodiesel including chemical inputs,energy and labor is $1.50 per gallon.And that's before including tax creditsfor alternative energy equipment. Processing Particulars

Before starting the process, the userfills the machine with 50 gallons of filtered, dewatered oil (the machine canalso assist in dewatering). The BioProcan process almost any non-petroleumnatural oil including, but not limited to,tallow, animal fats and vegetable oil.The waste vegetable oil gathered fromkitchens and restaurants is the mostcommon feedstock, but a vast variety ofother oils can also be used.

After filling the machine with oil,the user then adds a predeterminedamount of sulfuric acid catalyst followedby methanol. The user then presses theStart button, and waits for the mixing tobegin. There’s no need to monitor themachine while it does its work, whichcuts labor costs and ensures consistentquality and superior safety.

A multi-stage process begins toconvert the oil feedstock into ready-to-use biodiesel fuel. The first stage iscalled Esterification, or simply the“acid” stage.

During this stage, the machinemixes sulfuric acid and a portion of themethanol into the waste oil. The sulfu-ric acid modifies the free fatty acids sothe methanol can attach to them.When the acid stage is complete, theTransesterification or “base” stagebegins. The machine mixes the base cat-alyst and the rest of the methanol.Usually lye (sodium hydroxide -NaOH) or caustic potash (potassiumhydroxide - KOH) acts as a catalyst tobreak the molecules apart into glyceroland fatty acid chains. Immediately afterthe molecules are broken apart, themethanol attaches to the fatty acidchains, causing the glycerol molecules todrop out of the oil and become glycerin.During this stage the machine is mixingthe oil, chemicals and methanol togeth-er with an extremely powerful, tri-bladeimpeller. This helps to vigorously mixfluids and chemicals together to ensurethe oil is chemically altered.

After both reactions have occurred,the oil settles for a period of severalhours. The glycerin falls to the bottomof the tank and separates from thebiodiesel.

Following the settling period, theuser drains out the settled glycerin andbegins the washing cycle; this is the only user interaction required during processing.

In the washing process, themachine turns on the heat and lightlysprays a mist of clean, fresh water intothe biodiesel. Although it may soundstrange to add water to biodiesel, water is heavier so it quickly falls to the bottom.

As the water falls, excess methanoland soap molecules attach to the waterand fall with it, thereby cleansing thebiodiesel. Another mist wash is performed using the big tri-blade mixing impeller. We call this an agitatedwash cycle, and it’s used to pull impurities from the biodiesel.

Everything then settles for a fewhours, the water drains and another

16

User SolutionsAlternative Fuel

I


http://www.springboarddiesel.com

17



agitated mist wash starts. Upon comple-tion, the water settles to the bottom andis automatically pumped out by the machine.

After the wash water is drained, theheat remains on and the tri-bladeimpeller starts again. The combinationof heat and mixing evaporates excesswater from the freshly washed biodiesel.The biodiesel settles out one last time tofinalize the evaporation.

That's all there is to it. There’s noneed to transfer fluids from container tocontainer, as the machine does thisautomatically.

When processing is completed,users connect the hose to the includedfuel pump to fuel their vehicles.Automating the Process

Creating biodiesel from commonwaste oils is an interesting and some-what complex chemical processing oper-ation, but this complexity is unbur-dened from the end user by automation. The BioPro relies heavily onProgrammable Logic Controllers(PLCs) from AutomationDirect(www.automationdirect.com) to con-trol all the various functions of themachine, making the PLC the brains ofthe machine. For example, the PLC tellsthe machine when and how long mixingoccurs, when and how pumping occurs,when draining begins, etc.

We use the AutomationDirectCLICK PLC or the DirectLOGICDL105 PLC depending on the size ofthe machine. Since the CLICK doesn’trequire a mounting base, it works wellfor the smaller machines where space isat a premium. For the larger machines,we use a DirectLOGIC PLC because ithas more of the required discrete andanalog inputs and outputs.

We’ve written several programs forthe PLC which allow optional proce-dures to be automatically executedaccording to field conditions.

For instance, the PLC is preprogrammed to accommodate additional equipment that works withour processor systems, such asthe INCOSEP™, a device that can be

installed inside the BioPro 190 or the BioPro 380 that enables users to

more than double their biodiesel processing speed.

The CLICK PLC’s free program-ming software, downloadable from the AutomationDirect Web site, helpskeeps the price down on our smaller machines.

In addition to PLCs, we useNITRA pneumatic solenoid valves purchased from AutomationDirect forour pumps. Everything we use must behigh quality and durable, and we findthat AutomationDirect components fitthe bill. We tried a variety of solenoidsduring development that didn’t work aswell, so we decided on the higher quality NITRA solenoids to ensure thatour pumps operate smoothly.

We also use many signal conditioners from AutomationDirect,such as the FC-T1 thermocouple signal

conditioner, and we find that the DIN-mount adaptor makes installation easy.

We appreciate that AutomationDirectprovides quality and user-friendly products at a competitive price, butservice is also an important factor. We’rea company that prides itself on cus-tomer service and has a real person answer the phone when customers call, so we’re glad that whenwe need support, a real person atAutomationDirect answers the phoneand helps us in a timely manner.Quick Payback

Our machines span from theBioPro 150 which makes 40 gallonsevery 48 hours, to the BioPro380EX inline with a SpringPro T76 which makes

100 gallons every 13 hours. Cost pergallon is determined largely by the number of gallons made, and the cost ofthe oil feedstock.

For example, a university uses ourBioPro 380EX, which makes 100 gallons of biodiesel from 100 gallons ofcooking oil every 23 hours, to make2400 gallons per month. In this scenario, payback for the machine andlabor is achieved in only in three and ahalf months, assuming regular diesel isfour dollars a gallon.

We’re proud of our BioPros, but wearen’t stopping there. The CaliforniaEnergy Commission recently selectedSpringboard Biodiesel from numerousapplicants for a grant to assist with thecompletion of our new closed-loop production facility.

Continued, p. 19>>

CLICK PLC controls small BioPro machine.

BioPro fuel processing machines.




Download the free programming softwareand check it out!

AB

P3-HSI P3-HSO

Machine Process Start

1Enable

VELOCITY MOVEModule Name: Feed ConveyorChannel: 2 Channel Name: CHAN-2-0.1.1Move Setup Direction Positive Velocity Fill Index Speed 500 Ramp Rate Conveyor Ramp Rate 1000Stop Setup Immediate Stop

In Progress ConveyorMove In Progress 1Complete Conveyor Move Complete 0Move Status Conveyor Move Status 2

P3-HSO2-channel

High-speed Output

$349Pulse/Direction, Quadrature X1and Quadrature X4

P3-HSI2-channel

High-speed Input

$329Pulse/Direction, Step Up/Step Downand Quadrature

With the Productivity3000controller, you get the power youneed for advanced applications.

Start with the $599 CPU - 50Mb of memory supportslarge programs, with tagname database and programdocumentation stored onboard. The huge (100,000+)I/O capacity gives you plenty of room to plan andexpand. And the CPU’s seven built-in communicationports make integrating a large system easier thanyou can imagine.

Now with High-speed Motion ControlThese new 2-channel modules add high-speed and motioncontrol applications capability to the Productivity3000 controller,and they’re easy to use! Add up to 22 P3-HSO or P3-HSI modulesin any combination to any P3-550 CPU and P3-RS base group.That gives you up to 44 axes of motion or high-speed countingcapability in a single base group. These modules are supportedand fully functional in the CPU base, local and remoteexpansion bases.

Simple InstructionsOur standard instructions were designed to make youreveryday motion applications simpler. The Find Home, SetPosition, Simple Move and the Velocity Move instructions(to name a few) were created to get you up and runningsooner. Capabilities such as Registration, Jerk Control andChannel Scaling were included to give you the flexibilityto accomplish those jobs.

Drop-in Hardware ConfigurationInstall a high-speed module into the system hardwareconfiguration and define each channel’s behavior, status bits,limits and scaling … without the need for an externalconfiguration utility or software.

Application Example High-speed outputs synchronize thespeed of the servo drive controlling thefill conveyor. The conveyor issynchronized with the rotational speedof the turntable based on thesignal(s) from the tableencoder feedback via thehigh-speed input module.

http://bit.ly/p3000


http://bit.ly/p3000

http://www.productivity3000.com



For this project we will need moreinputs and outputs, so we’ve selected the Productivity3000 programmable controller from AutomationDirect.

For this larger application, wedecided on the Productivity3000because it provides a number of featuresthat we need, such as seven communication ports (includingEthernet), and built-in local I/O expansion capabilities. TheProductivity3000 is very competitive inprice, and combines the features andcapabilities of a PC-based control system with the cost and compact size ofa PLC.

We’re dedicated to supplying consumers with an economical way tocreate biodiesel in an automated processfrom materials that would otherwise bewasted or end up in landfills. As wekeep expanding our offerings, we will continue to rely on high-quality and cost-competitive automation components from AutomationDirect tomake our machines as economical as possible.

User Solutions Cont.

The Benefits of Biodiesel Fuel

• Burns 88 to 90% cleaner than regular diesel if made from waste cooking oil(http://www.arb.ca.gov/fuels/lcfs/072009lcfs_uco_bd.pdf)

• Burns 78% cleaner than regular diesel when made from virgin soybean oil (according to the EPA)

• Can be made from most any vegetable or animal oil

• Will run in virtually all diesel engines without any conversion equipment or modifications.

• Offers superior lubricity, creating less engine wear

• Mixes with hydrocarbon-based diesel in any ratio

Table 1

BioPro Features and Benefits

• Makes ASTM-D6751 grade biodiesel fuel

• Fully automated process that’s extremely easy to use

• Can make clean-burning renewable fuel for as low as 95 cents per gallon if feedstock oil is free

• Made from 304 stainless steel

• All motors and pumps are explosion proof

• CE certified

• Converts any oil that is 5% Free Fatty Acid Analysis (FFA) or less.

• More than 6.5 million gallons of annual installed capacity in 14 countries.

• On the campuses of 60 U.S. colleges and universities

Table 2

Alternative FuelContinued from, p. 17

“Employee of the month is a goodexample of how somebody can beboth a winner and a loser at the sametime. ”

– Demetri Martin

“If A equals success, then the formulais: A = X + Y + Z, X is work. Y is play.Z is keep your mouth shut.”

– Albert Einstein


http://www.arb.ca.gov/fuels/lcfs/072009lcfs_uco_bd.pdf


Product Manager’s Corner

20

Set Your PAC in MotionBy Jeff PayneProduct Manager; PAC/Programmable Relays AutomationDirect

he 2012 year has broughtmany new enhancements forthe Productivity Series control

platform; you will notice subtleimprovements to the software as well as major module additions such as the High-Speed Counter and PulseOutput modules. In this article we willreview these enhancements to offer a better understanding of current product updates.

The software has received severaladvances in our most recent releases.The enhancements were based on feedback and suggestions we receivedfrom our customers and from thoseusing the software utility on a regularbasis. Our goal is to continue toimprove the usability of the productuntil we are satisfied you have the bestprogramming tool in the industry.Bit-of-Word Data Types support

The addition of Bit-of-Word sup-port complements the use of arrays formanipulating individual bits of a word.You can now target individual bits of anInteger tag in any instruction thataccepts a Boolean tag.Data View Trend graph

The new trend graph addition tothe Data View gives you the ability toquickly chart Boolean tags or integervalues you are currently monitoring inthe Data View window. New Toolbars

New toolbars were added for theLadder view, Data View and TaskManagement panes to optimize spaceand improve the ease of use. Look formore of these toolbars throughout thesoftware as well as additional functionsto be added to these new toolbars.Tabular PID tuning window

You can now monitor and tune upto five separate PID loops in the PIDtuning window, giving you the abilityto more easily tune and adjust yourentire process.

Search & Replace Enhancements The latest improvements to the

Search and Replace feature include separate Tag, Comment and Instructionsearches and the capacity to Find andReplace partial tag names. This can beespecially beneficial when your applica-tion calls for extensive duplication. Forexample: Create one PID loop called“Oven1”. Then create and assign allassociated tags (Oven1_SP, Oven1_PV,Oven1_P, Oven1_I, Oven1_D, etc.).Now you simply Copy/Paste the firstinstruction in your ladder code andFind/Replace “Oven1” with “Oven2”,and your second PID is complete(repeat for as many instructions as you need).Add Multiple tags to Data View

With two mouse clicks (RightClick > Monitor in Data View) you cannow add all tags from a single instruc-tion, an entire rung or a group of rungsto a new Data View tab. This eliminatesa tremendous amount of time whentroubleshooting specific areas of code.Enhanced Print options

Customization was the focus whenworking with the latest print features.We discovered that users are looking fordifferent ways to print their ladder code,

so we added the ability to rung wrap andshow even the longest and most com-plex rungs on a single page, select thefont size, default font type and customfonts for each comment type, wiringlabels, System IDs, etc. Revamped Firmware upgrade tool

This now allows you to quicklycompare the Firmware versions, viewfirmware files offline and filter on themodule type(s).View Tag comments in the ladder

The new toolbars make it easier toadd some features. There are many view-ing options in the ladder code offeringmore customization and the ability tosee varying levels of detail. You havetoolbar icons for enabling and disablingTask comments, Run comments,Instruction comments, Tag names, Tagdetails and Block details. Enabling theTag details will show the comment fieldassociated with each tag from the Tag database. Task Management Sync

The Task management window iswhere you organize all program tasks.These tasks can be many and in variousfolders. The new “Sync with Editor”option ensures the task you select in theTask management pane is the

Programmable Automation Controller

T

Image 1: With the P3-550 CPU’s Integrated Web Access you can access Data Logger files stored on the connected USB device as well as read-only System Tags to view system status.


21


task you are currently viewing in theLadder editor.

Beyond this list of softwareenhancements are a couple of majoradditions to the product. First is thebuilt-in Web Access; with this you gainaccess to data log files stored on theremovable USB drive, system tags anderror and event history. This is an excellent tool when paired with thebuilt-in data logging feature of the P3-550 CPU. You can now accessprocess data from anywhere (with theproper provisions and security consider-ations). Simply configure your CPU’sdata logger to store files to the remov-able USB device port and enable theWeb server from your CPU’s hardwareconfiguration page. From here it merelyrequires you typing the IP address of theCPU into any browser and your data isat your fingertips. See Image 1.

Our latest hardware additionsinclude the High-speed counter input(P3-HSI) and Pulse output (P3-HSO)modules. These new 2-channel modulesadd high-speed and motion controlapplications capability to theProductivity3000 controller, and they’reeasy to use! Add up to 22 of these modules in any combination - that givesyou up to 44 axes of motion or high-speed counting capability in a single system.Drop-in Hardware Configuration

Install a high-speed module intothe system hardware configuration anddefine each channel’s behavior, statusbits, limits and scaling, all without theneed for an external configuration utility or software.Simple Instructions

Our standard instructions weredesigned to make your everyday motionapplications simpler. The Find Home,Set Position, Simple Move and VelocityMove instructions (to name a few) werecreated to get you operating morequickly. Capabilities such asRegistration, Jerk Control and ChannelScaling were included to give you theflexibility to accomplish those jobs.

Application ExampleIn the diagram, high-speed outputs

synchronize the speed of the servo drivecontrolling the fill conveyor. The conveyor is synchronized with the rotational speed of the turntablebased on the signal(s) from the tableencoder feedback via the high-speedinput module.

SummaryAll these features were designed to

help get your project up and running inminutes, not hours or days. Look foradditional enhancements to these mod-ules in the future.

We continually strive to improveour products and value your opinion.Please download the latest software revi-sion and take a test drive. If you havecomments or suggestion for improvingthe product further, please visit our sitebelow or contact our Technical Supportstaff at 1-800-633-0405.

For additional information onthese features and more, check out theProductivity Series Web site. www.productivity3000.com


Image 2: High-speed Application Example Diagram

“They usually have two tellers in mylocal bank, except when it's very busy,when they have one.”

– Rita Rudner

“I'm against picketing, but I don'tknow how to show it.”

– Mitch Hedberg


http://www.productivity3000.com


Tech Brief

22

ImportantConsiderations forReplacing and SizingAC MotorsHow to determine whetherto rewind or replace amotor, and how to find theright motor size for

your application.By Joe KimbrellProduct Manager; Drives, Motors and MotionAutomationDirect

very business is trying to conserve energy in the face ofhigh utility costs, so getting the

best return on investment (ROI) is critical for maintaining a healthy balance sheet. The decision to replaceexisting motors with newer premiumefficiency motors needs to take intoaccount both the increased energy efficiency as well as ROI gained byinstalling a new motor.Background on Classes of MotorEfficiency

There are three basic standards ofmotor efficiency: pre-EPAct, EPAct, andPremium Efficiency (also known asNEMA Premium). In 1992, theDepartment of Energy issued theEnvironmental Policy Act of 1992(EPAct ’92). This legislation set mini-mum standards for efficiency of themajority of general purpose motors soldin the U.S. The actual requirements formotors went into effect in 1997.Motors sold after EPAct ’92 went intoeffect are commonly referred to asEPAct motors.

In 2007, the Energy Independenceand Security Act of 2007 (EISA) wassigned into law. This legislation raisedthe minimum efficiency for most induction motors sold in the U.S evenhigher. The requirements for this lawwent into effect in 2010. Motors thatmeet the latest efficiency guidelines arereferred to as Premium Efficiency (PE)or NEMA Premium motors. Rewind or Replace?

One of the first decisions madewhen a motor fails is whether to rewindor replace the motor. The biggest determining factors in that decision arethe age of the motor, the type of motorinvolved, availability, how often themotor runs, and its efficiency. When apre-EPAct motor isn't working properly,replacement is most always preferred(age of the motor and gains in efficiencyplay a significant role in the ROI).

When an EPAct motor fails, theincreased savings of replacing this motorwith a Premium Efficiency motorrequires consideration. If a PremiumEfficiency motor fails, the repair/replacedecision becomes even less clear-cut.The Department of Energy has information that can help you determine the payback when decidingon purchasing a new PremiumEfficiency motor vs. repairing pre-Epact, EPAct, or existing PremiumEfficient motors.http://1.usa.gov/MS3AbN

In the past, rewinding a motor usually meant losing efficiency, butthat's no longer true, as original motorefficiency can be maintained in mostcases. In fact, it's sometimes possible toincrease efficiency with a motor rewind.To determine the effect on efficiency fora specific motor, experts at a motorrepair shop should be consulted.

When the motor in question is aspecial or custom motor, additional factors help determine whether to repairor replace, such as the longer lead timesrequired for custom motors, and thehigher costs of replacing them.

In these cases, rewinding may be amore attractive proposition. For non-custom standard efficiency motors,replacement is often the better way to go

because the efficiency gains usually outweigh the cost of a new motor.

The amount of time a motor runscan also help determine whetherrewinding or replacing is the betteroption. For motors that operate continually, the ROI for a new, premium efficiency motor can beachieved fairly quickly. For motors thatonly run periodically, careful analysis isneeded in the cost calculations forreplacing versus rewinding. To help withthese calculations there are several Websites, such as the Department of Energywebsite. The Department of Energyalso provides a free software package,MotorMaster+, which assists withmotor rewind/replace decisions, as wellas creating a motor survey if replacing isdetermined to be the better option.Considerations for Replacing a Motor

A common mistake that happenswhen the decision is made to replace amotor is thinking that buying any newpremium efficiency motor will deliveroptimal efficiency. When trying to boostsavings by increasing energy efficiency,selecting the right-sized motor is at leastas important as the energy efficiency ofthe new motor.

If the new motor is oversized, theenergy savings will be less than if theright sized motor was installed. The bestmethod for determining the right sizemotor is to conduct a thorough motorsurvey. Correctly sizing an AC motor isimportant because overloaded motorscan overheat, and underloaded motorswaste energy. A motor's energy usageaccounts for more than 95 percent of its lifetime cost, so achieving maximumenergy efficiency is crucial, and rightsizing the motor is a key step.Sizing and Output Speed

The two most important factorswhen sizing any type of load arerequired torque and speed. Finding therequired output speed is usually easilyaccomplished by determining the designspecifications. However, it's usuallymore difficult to determine the correcttorque.

A too-frequent problem in today'sindustrial applications is the use of oversized motors, an issue that can be

Sizing AC Motors

E


http://1.usa.gov/MS3AbN


addressed with more precise up-frontengineering. For example, if an application really requires slightly morethan 5 horsepower (hp) at infrequentintervals, a 7.5 hp motor is ofteninstalled to make sure there's enoughheadroom. In this situation, the 7.5 hpmotor will definitely work, but it will be running well below full load torque and further down the efficiency curve(wasting energy).

For applications that only requirethe motor to operate above full load forshort periods of time, selecting the rightsize motor with a higher service factorcould be a better option. For example, if a motor has a 1.15 service factor, itcan occasionally handle an additional15 percent load without damaging the motor.The Importance of a Motor Survey

Conducting a motor survey is thebest way to correctly size a replacementmotor. A motor survey should begin byreviewing and cataloging the nameplateinformation on the current motor toobtain the rated speed, efficiency, full-load current, etc.

The motor nameplate is the firststep of a motor survey. It supplies available information, such as speed andfull-load current, to help select the rightsize motor.

The next step is to use a clamp-onmeter to monitor the current the motoris drawing during normal operation.Most systems have many unknown factors, such as friction and mechanicaltransmission efficiencies, which affectmotor loading. Thus, getting an actualmeasurement of the current going intothe motor helps determine the truerequired motor size.


PLC Training at theUnited States Institutefor TheatreTechnology AnnualConference and Stage ExpoLoren Schrieber, ProfessorSchool of Theatre, Television, and FilmSan Diego State University

utomationDirect’s program-mable logic controllers werefeatured in a training center

hosted by the United States Institute forTheatre Technology (USITT) at theirannual Conference and Stage Expo heldin Long Beach, California, this spring.The training center was equipped withC-more Micro touch screens and bothDirectLOGIC DL05 controllers andCLICK PLCs.

Automation is no longer just forthe factory floor. The entertainmentindustry has also harnessed the latestgeneration of automation controllers’incredible power to make graceful scenechanges possible with the press of a

single button. From cats flying into theheavens on giant Michelins, Spidermanchasing super-villains over audiences onBroadway, to the incredible effects-driven Las Vegas shows such as “O” and“KA,” automation devices have becomeindispensable to theatrical productionsat every level.

Recognizing that training is key tosafety in automation, USITT solicitedthe help of the San Diego StateUniversity School of Theatre,Television, and Film—one of a handfulof schools with a formal program in theatrical automation—to set up thetraining center at Stage Expo. Bothgraduate and undergraduate studentswere involved in the project.

AutomationDirect’s price advantageand outstanding service made them thePLC vendor of choice. Students assembled four DL05 stations, eachdemonstrating a different automationconcept. One station used a proximityswitch reading the teeth of a motor-driven sprocket to illustrate the use ofcounters. The second used pulsed outputs to drive a stepper motor. Thethird station was equipped with an F0-2AD2DA-2 analog module whichdemonstrated input and output of continuously variable data, while thefourth was used to read the output of an

Student SpotlightSan Diego State University

A

Continued, p. 24>> Continued, p. 27>>



24

incremental encoder and display resultson an 8-inch C-more color touch screen.

CLICK PLCs were used morewhimsically. Students were assigned inpairs to create machines of their choos-ing, which the CLICKs would control.Each machine was required to incorpo-rate the C-more Micro touch screenswhile demonstrating the use of timersand counters.

One team built a ping pong ball aircannon with CLICK-controlledazimuth and elevation, countdowntimer and valve trigger all initiated by aretro-reflective beam detector. Thisproved to be the most popular machine,with trainees attempting to pummeleach other with ping pong balls.

The second team built a machinewhich, when activated by pressing agreen GO button, simply turned itselfoff by extending a pneumatic finger to

press a red STOP button. Every third orso attempt to turn itself off was programmed to fail and the fingerwould have to bump the STOP buttonseveral times in frustration before shutting down.

Another machine consisted of aDirectLOGIC DL-05 PLC connectedto a pneumatic bell. At the push of abutton, a pneumatic claw reached up topull a plastic ball down against a spring.Once in the cocked position, a secondpneumatic cylinder pulled the clawback, launching the ball to strike thebell; because the bell was VERY loud,this machine became very annoying.

The final machine was a simpleelectronic piano played with pneumaticfingers. A slight miscalculation in thelength of the fingers gave a whole newmeaning to piano as a percussion instrument; it eventually beat itself to death.

At each of the stations, traineeswere shown the ease of ladder logic andstage programming. Most participantswere astounded at how easy it was tobuild a useful program with simple diagrams. The limited version of theDirectLOGIC software and the completely free CLICK software areboth available for download from theAutomationDirect Web site.

Having practical applications andanimated devices as part of the trainingcenter made for a very exciting exhibitvisited by scores of conference attendees.USITT would like to thankAutomationDirect for making the training center possible.

Student Spotlight cont.San Diego State UniversityContinued from, p. 23


25



Business NotesGoings-on in the IndustryBy Joan Welty

Free shipping on ordersover $49 to U.S. andCanada

e’ve lowered the free ship-ping threshold to orders of$49 and over. Now you

can order any time, anywhere, and formost all your orders, not have to worryabout shipping costs or delivery time!We use our choice of carrier and a combination of ground and air servicesthat allow us to reach any U.S. destina-tion within 2 days transit time (or less).(Note that while the 2-day transit timedoes not apply for LTL shipping ofheavy items, or drop-shipped (notstocked in Cumming, GA) items, thoseparts are included in calculating yourorder value to reach the $49 threshold.)And orders under $49 in the U.S. shipstandard ground at a flat rate of $6,unless you choose an alternate shippingmethod (which will incur the appropriate shipping charge).

We also now offer LTL shippingcapability to Alaska, Hawaii and PuertoRico. We have always been able to shiplightweight orders to those destinations;now heavy items or orders can go aswell. If an order qualifies for free ship-ping, the lightweight parts can beshipped at no charge; however, heavyitems or orders that must ship LTL willincur a charge; please call the SalesDepartment for an accurate quote.

Free shipping is also available toCanada for orders totaling over $49U.S. (shipped via our choice of carrier,typically air service), except for items ororders that may require LTL shipping.Heavy items requiring LTL transitalways incur shipping charges; however,their value is used to calculate if anorder is over $49 total. Heavy orderswhich would otherwise qualify for freeshipping may require LTL transit andthus an LTL shipping charge.

We’ve streamlined our brokeredservices to Canada as well. For ordersshipped via air service, any applicableshipping charges include brokerage fees.For orders $49 U.S. and over, brokerage fees are included, and

AutomationDirect nominates the broker. Note that if you allowAutomationDirect to broker any LTLshipment, you can take advantage ofour flat rate charge based on weight;charge includes freight costs to the specified address on the order, and brokerage fees. With the flat rateoption, duties and taxes will be added tothe order at checkout. See the CanadaFlat Rate Table in our updated Termsand Conditions online to determinebrokered LTL shipping charges.

See our updated Terms andConditions online for full details andlimitations. Just one more way we hopeto make you a satisfied customer!

C-more Micro how-to series of 84 videos now on www.C-moreMicro.com

he C-more Micro panel seriesare easy-to-use small operatorpanels for control systems.

But if you need some help getting start-ed, or have a question on a specifictopic, you’re likely to find the answers inour newly posted series of C-moreMicro tutorial videos. Topics range froman overview and “quick start” todetailed explanations for implementinganimated graphics.

For all videos, visit:http://CmoreMicro.com/support/video.htmlor www.youtube.com/automationdirect

W

T

“I love deadlines. I love the whooshingnoise they make as they go by.”

– Douglas Adams



http://www.C-moreMicro.com

http://CmoreMicro.com/support/video.html

http://www.youtube.com/automationdirect


1-800-633-0405


AutomationDirect now offers a variety of protective glovesfor industrial or other hazardous environments. From light-weight nylon to leather or steel-core yarn, you’ll find whatyou need for specific working tasks. Cut resistant glovesand sleeves meet the ANSI standard up to cut level 5. Mostgloves are available in sizes from extra-small to 2XL.

Prices start at just $7.00 for a six-pair package of generalpurpose polyurethane-coated nylon gloves.

Arc Flash & Cut Resistant Gloves$19.00 pr.( TTP203 Series, leather )

Industrial Work Glovesfor Hand Protection

• Safety Glassesstarting at $2.75 (SG-754)

• Safety Light Curtains, Relays and Switches

Also Available

www.automationdirect.com/safety

Puncture / Impact / CutResistant Gloves$29.50 pr.( TTP455 Series )

Cut Resistant Gloves$7.00 pr.( TTP050 Series, with polyurethane palm)

www.automationdirect.com/work-gloves

• General Purpose Working Gloves• Anti-Static Gloves• Arc Flash / Cut Resistant Gloves• Cut and Puncture Resistant Gloves• Mechanics Style Gloves• Impact / Puncture / Cut Resistant Gloves• Cut Resistant Sleeves

In-stock to ship same day,and free shipping onorders over $49



http://www.automationdirect.com/safety

http://www.automationdirect.com/work-gloves

By Chip McDaniel

BrainTeasers

Cable Tie-up I

1.) Can you remove four cable ties fromthe following arrangement and leavefour equal size triangles with no extra“offshoots” or loose ends?

The Curly Shuffle

2.) A factory has three CNC machines- each with its own operator. One day alarge order is received and Larry quicklyboasts “Curly and I can produce allthose parts in ten days, but if you letMoe help me instead of Curly, we cando it in 9 days”. Curly is offended, andreplies “Forget about Larry, if Moe andI produce the parts, we can finish in 8days”.

How long would it take each CNCoperator to produce all the parts on hismachine individually?

Widgetry

3.) During the morning shift the proba-bility of a widget passing by a certainsensor (on a conveyor belt) in a 20minute window is 0.9. What is theprobability of a widget passing that sensor in a 4 minute window? Pleaseassume a constant probability through-out the shift.

Cable Tie-up II

4.) Starting with the arrangementshown above can you move only six ofthose cable ties and produce a patternwith five (unique) squares? No doubling-up the cable ties or loose ends,please.

Did you know that AutomationDirectsells cable ties starting at well under apenny apiece? Visit: www.AutomationDirect.com/cable-ties for more information and tosee our great prices!

27


The Break RoomBrainTeasers

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

“All I've ever wanted was an honestweek's pay for an honest day's work.”

– Steve Martin

“Be yourself; everyone else is alreadytaken.”

– Oscar Wilde

“If you can dream it, you can do it.”

– Walt Disney

Motors operate most efficientlynear full load, so determining loadrequirements accurately is important.The greatest efficiency is achieved above70 percent of full load torque. Below 50- 60 percent, efficiencies start to dropoff dramatically.

There are several web sites thatprovide information on how to determine motor load size, such ashttp://1.usa.gov/LDOEbW.

Conducting a thorough motorstudy may seem like a complicated task,but there are tools available to help withthe calculations.

Moreover, investing the time toconduct a thorough motor survey willhelp ensure the correct size motor, onethat will deliver maximum savingsthroughout the motor's life.

A wealth of additional information(motor survey forms, case studies, software tools, and fact sheets) can befound at the Department of Energy’sWeb site:www1.eere.energy.gov/manufacturing/tech_deployment/motors.html.

Continued from, p. 23

Tech Brief cont.Sizing Ac Motors

“I've learned that people will forgetwhat you said, people will forget whatyou did, but people will never forgethow you made them feel.”

– Maya Angelou

http://www.AutomationDirect.com/cable-ties

http://1.usa.gov/LDOEbW


http://www1.eere.energy.gov/manufacturing/tech_deployment/motors.html

PremiumEfficiencymotors thatpay forthemselves...

IronHorse™ Premium Efficiency AC electric motors meet therequirements of the Energy Independence and Security Act of 2007.Starting at $155, the MTCP Series gives you a low cost of entry so youget a quicker payback on your investment. All our Ironhorse motorsare in stock and ready for same-day shipment; if your order is over$300, you get free shipping too!


1-800-633-0405


AC T-Frame

AC TC-Frame

Features• Meets or exceeds Premium Efficiency standards• T-frame motors from 1 to 200 hp;

TC-frame models from 1 to 100 hp• T-frame EPACT motors in 250 and 300 hp also available• 1200, 1800 and 3600 rpm, electrically reversible• Ribbed frame design for maximum cooling• Maintenance free bearings (10hp and below)• V-ring shaft seals on drive end and on opposite drive end• Class F insulation• Class I, Div 2 hazardous locations• cCSAus certified, CE• Two-year warranty

• Inverter-dutyAC motors up to 100 hp,starting at $143

www.automationdirect.com/motors

• Single-phase andThree-phase Rolledsteel general purposemotors up to 2 hp,starting at $79

• DC motors up to 2 hp,starting at $133

http://bit.ly/adcmotors


http://www.automationdirect.com/motors

http://bit.ly/adcmotors

automation notebook magazine issue 23, summer 2012 from

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