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AUTOMATION

LATEST DEVELOPMENTS IN PROCESS & CONTROL NOVEMbER 08 - MARCh 09

INSIDE...
PLCS hUMAN MAChINE INTERFACES TEMPERATURE CONTROLS SOLID STATE RELAYS

06 08 10 14

04 Your guide to selecting the right PLC


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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.

2 AUTOMATION NOVEMbER 08 - MARCh 09

WELCOME

CONTENTS
Whats inside this issue...

04 06 08 10 13 14 15 16

PLC Guide PLCs

Selecting the right PLC


Page 4

Selecting the right PLC

Your choice of compact or advance

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.

hUMAN MAChINE INTERFACE TEMPERATURE CONTROL

Improve your temperature control process

TEMPERATURE & PROCESS CONTROL


Products from Omron

SOLID STATE RELAYS AUTOMATION PRODUCTS KNIPEx ThE PLIERS COMPANY


Pioneer ideas in pliers

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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.

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AUTOMATION NOVEMbER 08 - MARCh 09 3

Selecting the right PLC for your application


Choosing the right programmable logic controller (PLC) platform for your application and ensuring it meets the requirements of the process today and in the medium term, can be daunting. Whether its a brand new process, or replacing an existing out-dated controller the steps and considerations are fundamentally the same.
Understanding your machine or process is essential and drawing a simple block diagram of it will help identify the control devices and their physical locations. This will help in planning the PLC system design, calculating the level of I/O and considering network or distributed control selection. Once the control device requirements and combinations have been defined, you can now start the process of selecting a PLC platform that meets the needs of the process. Type of I/O Digital Input (I) Analogue Input (I) Digital Output (O) Examples Pushbuttons, limit-switches, float-switches, feedback from contactors (N/C or N/O circuits auxiliary circuits) Thermocouples, process transducers (pressure, linear, or current/voltage) Relay output or Transistor outputs. Relay is easy to work with, but transistor is more reliable and ideal for higher speed or repeated switching Proportional voltage of current output. Typically 0-10V or 0/4-20mA ideal for speed control of inverters, DC motor controllers and to panel meters.

Analogue Output (O)

4 AUTOMATION NOVEMbER 08 - MARCh 09 2008

Are you replacing an existing system?


Are you upgrading or replacing an old system that you can no longer get support for, or fails to meet the changing needs of the process? It is unlikely that the program from the old PLC will work with the new PLC platform, especially if they are different manufacturers, but the basic flow of the program logic will be the same and can be used as the basis for programming the new system. The existing control network could be used by the new system check the protocols being used.

PLC Processor performance and memory requirements


Three common levels of processor performance are available from each manufacturer. Logic controller Sometimes called a smart or programmable relay. Simple to program and cost effective for low I/O, slower speed, applications. Compact PLC - An intermediate level offering increased instruction sets and higher I/O capacity than a logic controller. Advanced PLC Offering greater processing power, larger memory capacity and even higher I/O expandability and networking options. Greater I/O requirements increase the processing time for each CPU cycle as the PLC processor has to respond to an increased number of inputs. This processing time is more critical as the controlled process speed increases. The following chart gives PLC platform performance positioning to help you select the level of processing power required for your application.
Logic Controllers Compact PLCs Advanced PLCs

What are the I/O requirements?


From the process diagram you can quantify the amount of digital and analogue inputs & outputs required. The digital outputs could be either a relay or a transistor output, however solid state switching is more reliable. Therefore using a transistor output to control a suitable solid state relay will be more cost effective in the long term due to reduced failures and maintenance.

Logo!

S7-200

S7-300C

Are there special I/O requirements?


Some of the I/O may require special inputs and many PLC platforms offer specialty modules that provide inputs and outputs not native to the PLCs basic capability. These modules provide inputs pre-configured for devices such as temperature sensors (PT-100 or thermocouple), or high-speed counters (>50Khz) for use with shaft encoders or resolvers.
Alpha FX1N & FX2N

FX3N Q Series Q00,01

Zelio

Twido

Modicon M340 M340c

Zen

CP1L CP1A, 2A

CJ1M CQM1/1H

Are there any environmental issues to be considered?


Will the environment in which the controller and process be operating see extremes of temperature or humidity? To ensure maximum reliability the controller must be kept dry and within its operational temperature range.

Easy 500 & 700

Easy 800 EC4P

XC Series

CompactLogix MicroLogix 1100, 1200, 1500 SLC500 Modular

What communication networks are required?


Various industrial control protocols are in use today. These include DeviceNet, Profibus, Ethernet/IP, CANopen, ModBus, DH-485 and basic ASCII over RS-422A & RS-232-C. The choice of communication protocol selected will be driven by a need to communicate with other existing equipment and any protocol this equipment uses. Many modern PLC systems offer multiprotocol communication and the option of a variety of modules to support various networking formats. www.rsaustralia.com 1300 656 636

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.

AUTOMATION NOVEMbER 2008 AUTOMATION NOVEMbER 08 - MARCh 09 5

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

$1,300.00 $1,750.00 $1,300.00 $1,750.00

S7-200 SERIES PLCs


The long term successor to the highly successful S5 range, whatever the S5 can do, the S7 will do it faster and easier, with built-in communications and improved programming software.
EEPROM memories for user program storage 4KB programme memory, 2KB data memory 0.22s processing speed S7-221 CPU: 10 on-board I/O S7-222 CPU: 14 on-board I/O

S7-200 SERIES ExPANSION MODULES


Digital and analogue modules to increase I/O capacity in AC and DC powered options. Options include standard I/O and special function modules for PT100 temperature probes and Ethernet communications.

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320-9109 FX2N-16EX-ES/UL 186-5842 FXON-3A 320-9171 FX2N-HC 399-7806 GX developer FX

$453.00 $446.00 $830.00 $970.00

TWIDO COMPACT CONTROLLERS


User friendly and flexible controllers with powerful control functions and small footprint design making them suitable for use in applications where space is limited.
24Vdc inputs Isolated outputs
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Windows based programming software

488-6757 S7-221 6 I/P 4 transistor O/P


(24Vdc)

$323.00 $355.00 $499.00 $520.00 $1,140.00

468-5762 16 I/P digital input module 434-1816 4 channel analogue I/P


module

$303.00 $440.00 $476.00 $650.00 $1,190.00 $730.00

Relay outputs rated at 2A 250Vac Transistor outputs rated at 0.3A 24Vdc

488-6735 S7-221 6 I/P 4 relay O/P


(85-246Vac) (24Vdc)

434-1822 2 channel analogue


O/P module I/P module module

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

539-0162 S7-200 starter kit

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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

$287.00 $287.00 $267.00 $600.00 $456.00

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6 AUTOMATION NOVEMbER 08 - MARCh 09

444-4707 Programming software

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

$990.00 $1,230.00 $510.00 $371.00 $407.00 $2,280.00 $137.00

SIMATIC S7-300 SERIES CPUs


A modular mini-PLC system designed for the low-end and mid performance applications offering user-friendly handling and uncomplicated performance in a fan-free design.
S7-312C With integrated inputs and outputs Ideal for small applications with high requirements in terms of processing power With process-related functions S7-313C With integrated digital and analogue inputs and outputs For installations with high requirements in terms of processing power and response time With process-related functions S7-313C-2 DP With integrated digital I/O and PROFIBUS DP master/slave interface For tasks with special functions and the connection of standalone I/O devices

MODICON M340 AUTOMATION PLATFORM


Robust, powerful and compact, the new Modicon M340 PLC offers the optimum response to the needs of machine manufacturers in the fields of secondary packaging, materials handling, textiles, printing, food processing etc.
Data rate 20KB/s to 1MB/s Integrated 3 communication ports Counter modules with ready-to-use functions SD Memory Card slot Remote access via STN, GSM, Radio or ADSL Modbus serial link or character mode

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148-177 148-155 148-149 148-183 147-641 147-988 147-770

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

$850.00 $1,790.00 $212.00 $310.00 $368.00 $800.00 $1,600.00

CJ1M SERIES PLCs


A modular system offering a wide range of connection options from Serial to Fieldbus and Ethernet, ideal for applications requiring up to 640 I/O points.
RS-232 ports
Memory Card interface

Peripheral port
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Data memory 32K words

211-152 227-854 211-427

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

$950.00 $2,040.00 $2,600.00 $323.00 $342.00 $114.00


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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

$780.00 $1,040.00 $365.00 $540.00 $430.00 $970.00 $3,080.00

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AUTOMATION NOVEMbER 08 - MARCh 09 7

hUMAN MAChINE INTERFACES


E-SERIES hMI PANELS
A perfect blend of operator friendliness and powerful performance, with free software drivers, backlit monochrome LCD display and password protection.
Multi-language Upgradeable firmware Windows programming tools IP65 panel sealing

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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

$600.00 $1,220.00 $257.00

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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

MAGELIS xbT-N DISPLAY UNITS


Designed for use with Telemecanique Twindo, Nano, Micro and Premium PLCs to display status messages, alarms and maintenance information as well as process data.
2 fixed legend, service keys (ESC, ENTER) which are non-configurable 2 fixed legend, left and right arrow keys, configurable as links to different pages or for machine control 4 configurable and legend customisable keys Configuring Windows software available separately XBT-N200 Alphanumeric LCD display with green back lights 2-lines of 20 characters Powered by the PLC XBT-N401 LCD matrix display with green, orange or red back lights 4-lines of 20 characters Communication, alarm and PLC controlled LEDs 24Vdc power supply Group and Category: IIC T5 Ex D A22

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510-1849 NT3S-ST126BE 510-1861 NT3S-ST123BE 510-1984 Programming cable 2m

$810.00 $940.00 $61.90

493-3409 XBT-200 493-3421 XBT-401 493-3437 XBT-L1001M software

$285.00 $570.00 $600.00

8 AUTOMATION NOVEMbER 08 - MARCh 09

hUMAN MAChINE INTERFACES


SIMATIC TP177b PANELS
These panels are designed to enable you to use more efficient text or graphic-based projects for simple to medium level HMI tasks in machines and plants.
STN LCD touch screed display Numeric and alphanumeric inputs FLASH memory Colour: 256 colours, RS-232/485, USB, MMC and RJ45 interfaces Monochrome: 4 shades of blue, RS-232/485, USB and MMC interfaces

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617-3340 Monochrome display 617-3334 Colour display 617-3378 WinCC flexible compact software

$2,260.00 $3,100.00 $580.00

E-SERIES TOUCh SCREENS


Feature packed and offering a blend of operator friendliness with powerful performance, they are suited to a wide range of applications.
Real time clock Backlit graphics display Windows based programming RS-232/485/422 ports 24Vdc supply Monochrome: 3.8 display, 16 grey scales Colour: 5.7 display, 256 colours

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xbTGT2000 SERIES TOUCh SCREEN DISPLAYS


Compact, rugged and designed to facilitate your operator dialog operations. Featuring two serial interfaces (RS232C-RS422-RS485) to connect to automated systems, and a powerful suite of graphic functions.
Colour or monochrome options 5.7 screen size supporting 4,096 colours USB port Analogue touch pad (1024 x 1024dpi resolution) Vijeo Designer, a single software package for the entire Magelis XBTG/GT/GK/GTW range 16MB internal memory and CompactFlash Card slot (128Mb to 1Gb)Password protection On-board scripting 24Vdc operation

514-2581 Monochrome display 456-4952 Colour display 399-6241 Programming software

$1,630.00 $3,160.00 $257.00

NS5/NS8 VERSION 2 COLOUR TOUCh SCREENS


High quality interfaces for systems and machines controlled by Omron PLCs via an RS-232C connection at up to 115KB/s, giving high speed response to system and machine events and user input.
Two RS-232 and a USB ports
CompactFlash slot

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

$2,280.00 $1,550.00 $417.00 $910.00

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617-3104 NS5 screen 617-3126 NS8 screen 510-1956 Programming software

$2,920.00 $4,380.00 $1,100.00

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AUTOMATION NOVEMbER 08 - MARCh 09 9

TEMPERATURE CONTROL

Improve your temperature control process


Investing in modern temperature control equipment can provide returns instantly, improving product quality, consistency and reducing energy waste. PID temperature controllers are now even easier to install and setup, with automatic self tune features. This allows them to be quickly retrofitted in place of existing On-Off controllers without specialist knowledge.
basic On-Off Control
Process temperature fluctuates above and below the set-point.

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

10 AUTOMATION NOVEMbER 08 - MARCh 09

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

The language of temperature control


Autotune
Modern microprocessor based PID temperature controllers offer an in-built automatic self tune function. Once installed this tuning function is selected and automatically adjusts the controller parameters for the specific process. The Autotune function performs pre-set cycles turning the heating element on and off, and using a complex algorithm, calculates the optimum Proportional, Integral and Derivative parameters. By adjusting these initial PID settings, the self tune function will configure the controller to inhibit overshoot and compensate for the rate of change within the process. This gives the best straight line control response and reduces your engineering and commissioning time.

Page 1,576

Temperature Control Solutions

454-2205 454-2211 612-5638 538-3120

Relay O/P 100-240Vac Relay O/P 24-48Vac/dc DC SSR O/P 24-48Vac/dc PSI-CON configuration software

$512.00 $587.00 $599.00 $192.00

EUROThERM 3208 TEMPERATURE/PROCESS CONTROLLERS


Easy to use, innovative controllers offering precision control of temperature and other process variables, together with a host of advanced features not normally found in this class of controller.
Eight segment programmer Heater failure detector Modbus communication Analogue re-transmission 18 DIN 48 x 48mm mounting 85-264Vac supply

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

1 logic, 3 relay outputs 4 relay outputs

$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.

TEMPERATURE CONTROLLERS WITh COMMUNICATIONS


Series 3300 and 9500P DIN mounting temperature controllers with autotune function for tuning to optimum PID values.
IP66/NEMA 4X protected front fascia All can be used with Type B, E, J, K, L, N, R, S and T thermocouples and with PT100 RTDs Optional RS-232 and RS-485 communication boards enable PC connection via ModBus RTU protocol All 9500P series outputs and 3300 series first relay outputs are rated 2A at 250Vac

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.

Page 1,578 & 1,579

312-1784 511-8897 348-8863 312-1807 312-1813

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

$322.00 $329.00 $524.00 $132.00 $132.00

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AUTOMATION NOVEMbER 08 - MARCh 09 11

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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PID TEMPERATURE CONTROLLER


The 116th DIN PID500 is superb value, with a fully featured auto-tuning PID controller with selectable thermocouple, RTD or analogue inputs and available with relay and SSR outputs Dual display of set-point and process value Inputs: J, K, T, R, S, C, E, B, N, U, W , PT100 2/3 wire, 0 to 10V, 0 to 20mA Dimensions: H48 x W48 x D107mm

163-429 163-435 163-441 163-413

85-270Vac SSR output 85-270Vac relay output 24Vac/dc SSR output 24Vac/dc relay output

$510.00 $499.00 $510.00 $499.00

DIN RAIL MOUNT DIGITAL ThERMOSTAT


The eTron T offers a cost effective solution for users wishing to add a basic temperature control function to an existing cabinet installation for example fan control.
PT100 sensor input Adjustable switching hysteresis 3-digit LCD with either C or F selectable 10A / 250V changeover relay output
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497-8991 497-8985 497-8979

eTron T 230V eTron T 115V eTron T 12-24Vdc 24Vac

$200.00 $202.00 $200.00

163-356 163-390 163-362 163-378

85-270Vac relay output 85-270Vac SSR output 24Vac/dc relay output 24Vac/dc SSR output

$286.00 $303.00 $286.00 $303.00

Choosing the right temperature sensor


Choosing the right temperature sensor is key to the accuracy and stability of the whole temperature control system. In general, the choice is split between two types of temperature sensors: 1. Thermocouples
Thermocouples are constructed by joining two dissimilar metals together at a junction. Thermocouples exhibit the greatest ability to endure thermal and mechanical extremes. This makes them suitable for applications where robustness and durability is more important than absolute accuracy. The wide choice of thermocouple types and materials provides a range of operating temperatures, but generally a thermocouple is only the preferred option if the operating temperature of the process exceeds 350C. Thermocouples are a cost effective solution, however the connection between the sensor and the controller must be made using appropriately matched cable and ideally the connection distance should be kept to a minimum. Failure to use the correct extension or compensating cable will cause errors in the reading and instability with changes in ambient temperature. In electrically noisy environments with motors or large switchgear it is recommended that screened cable is used to prevent interference and unstable readings.

2. RTD Resistive Temperature Detector PT-100 / PT-1000


RTDs or Platinum resistance thermometers, sometimes referred to as PRTs, are temperature sensing devices that change resistance proportional to the temperature. A PT-100 device will have a resistance of 100 ohms at 0C, and a PT-1000 device 1000 ohms at 0C. RTD sensors offer excellent accuracy over a wide temperature range (from -200 to +850C ), but are particularly suited to applications with a process temperature of -100 to +250C. Unlike thermocouples, it is not necessary to use special cables to make the connection between sensor and controller. Most temperature controllers that support RTD sensors offer either a three or four wire connection mode. This allows the unit to eliminate any additional resistance in the cable and therefore longer cable runs of 20m or more are possible without compromising the system accuracy.

12 AUTOMATION NOVEMbER 08 - MARCh 09

TEMPERATURE & PROCESS CONTROL

Temperature & Process Control


From monitoring to control of single or multi-loop systems, Omrons extensive knowledge and technical expertise offers solutions for a variety of applications.
With both ON/OFF and 2-PID control as standard on all Omron digital controllers and advanced features like RT (Robust Tuning), Cascade Control and GTC (Gradient Temperature Control) available with more advanced models, the best control method can be selected for the application. Why 2-PID? Simply better control. Conventional PID uses a single function block to control the responses of the controller to a target value and external disturbance. Therefore, the response to the target value will oscillate due to overshoot if importance is attached to the response to external disturbance. On the other hand, if importance is attached to the response to target value, the controller will not be able to respond to disturbances quickly. It will be impossible to satisfy both these types of responses using conventional PID. 2-PID control eliminates this weakness while retaining the strengths of PID control, thus making it possible to improve both types of responses and hence overall process quality. Omron also offers a range of monitoring products where control is not a requirement. Suitable for displaying or policing a process, they indicate when the process exceeds preset alarm values, either via the easily visible colour change display or a series of alarm outputs.

Monitoring Products:

PROTECT YOUR hEATING APPLICATION


Designed specially for monitoring abnormal over or under temperatures. This temperature monitoring relay can prevent excessive temperature increase and therefore protect equipment.
Slim design, 22.5mm width
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100 to 230Vac supply

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:

ThE EASY WAY TO PERFECT TEMPERATURE CONTROL


Multi-range temperature controller with alarm function offers field selectable PID or ON/OFF control. The large, single display shows process value, direction of deviation from set point, output and alarm status.
Thermocouple and RTD (PT100) input Simple dip switch setting for standard functions
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hIGhLY VISIbLE LCD DISPLAY TEMPERATURE METER


Equipped with the same high quality colour change display, with two colour (red and green) LEDs, both temperature meters are highly visible.
Thermocouple / RTD input DIN 96 x 48mm, with short depth 80mm
Page 1,379

1 C/O relay output

DIN 48 x 48mm 100 240Vdc supply

611-7750 611-7744

K3MA-L-C K3MA-L-C

Temperature meter, 100 240Vac Temperature meter, 24Vac

$338.00 $338.00

611-9885 611-9879

E5CSV E5CSV

Temperature controller, 12Vdc pulse output Temperature controller, SPST relay output

$303.00 $303.00

hIGh-SPEED, hIGh-PRECISION TEMPERATURE INDICATOR


High speed, with a sample rate of 50Hz, these indicators also feature a clear and easy-to-use dual colour-change display, with two lines for actual value and set-point.
Optional communications cards are available, such as DeviceNet, RS-232C Output and option slots option boards not compatible with K3N models DIN 1/8 and IP66 housing. 100 240Vac
Page 1,380

COMPACT AND INTELLIGENT GENERAL-PURPOSE CONTROLLERS


The E5_N range of temperature controllers features a high-intensity three colour PV change dual LCD display with a wide viewing angle for easy status recognition, except for the E5GN.
Multi-input types, thermocouple/Pt100 100-240Vac Available in four standard DIN formats

Page 1,581

481-9274 512-6393 512-6371 512-6387

E5CN-R2MT E5AN-R3MT

Temperature controller, DIN48 x 48mm, relay output Temperature controller, DIN96 x 96mm, relay output

$407.00 $767.00 $509.00 $509.00

611-7558 611-7671 611-7637 611-7659

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

$698.00 $132.00 $136.00 $158.00

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

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AUTOMATION NOVEMbER 08 - MARCh 09 13

SOLID STATE RELAYS

Start using solid state relays today


The fundamental functions within the majority of process control systems involve repeatedly performing a switching action. Solid state relays (SSR) offer the user many outstanding benefits for this type of switching. Selection and application is easy and here are a few simple guidelines and suggestions to help you make the most of this technology.
What is a Solid State Relay?
A Solid State Relay is a switching device which uses transistor technology instead of mechanical contacts to do the switching function. This switching is performed by a Triac or SCR (Silicon Control Rectifier) dependant on the load type. Both these switching devices are members of the Thyristor family, and input to output isolation is achieved by the use of an optocoupler.

Typical SSR Internal Construction Typical Hockey Puck type SSR

Advantages of solid-state v electromechanical relays


Advantages: Long life and high reliability, more than 109 operations, reduced maintenance costs No contact arcing, low Electromagnet Interference (EMI) and high surge capability High resistance to shock and vibration Fast switching and low coupling capacitance Logic compatibility and no electromechanical noise Disadvantages: Higher cost than equivalent electromechanical relay Higher heat dissipation requires heat sink

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.

AC Motor and Coil Control Applications


Because of the inductive nature of AC motors, and solenoid coils, high surge currents occur at switch-on. This makes random or instantaneous turn on SSRs the most suitable type. When selecting a suitable SSR for these applications you must consider the following: Full Load current of the motor or coil Line voltage being switched Starting duration and frequency repeated cycles will increase thermal stress on the SSR requiring extra heat sinking or overrating Ambient temperature and available heat sinking Due to the high current during start-up the SSR must be over rated, compared to the full load motor or coil current. For motors, external over current protection is always advisable to protect both the motor and the solid state relay. This could take the form of a motor protection circuit breaker or thermal overload. Voltage selection is important as back EMF generated during motor wind-down or turn-off of a large coil can be x1.5 x2.5 line voltage. To ensure the maximum operational life the selected SSR, it should have a current rating of at least 3x the full load current, random turnon, and an over-voltage rating of more than twice the line 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.

Selecting the correct SSR for your application


Two output types exist within AC switching SSRs. The first is commonly referred to as Zero Voltage or Zero Crossing turn-on. This type only starts to conduct once the AC line voltage has passed through the zero volt point. The second type is referred to as random or instantaneous turn on. This type begins to conduct as soon as the control voltage is applied regardless of the AC line voltage.

14 AUTOMATION NOVEMbER 08 - MARCh 09

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

DIN RAIL 16A IMPULSE RELAYS


Unlike a standard relay, these step or impulse, relays alternate between two contact states on each successive coil energisation. Once power is removed the relay holds this contact state until the next coil input occurs. Ideal for any sequential or push-on, push-off application including lighting, door or gate control, and in security or alarm applications.
17.5mm wide module TS35 DIN Rail mounting

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479-3576 479-7231 479-3908

Green 1 N/O contact White 1 N/O I symbol Black 1 N/C 0 symbol

$14.40 $15.10 $25.20

Minimum impulse duration 0.1sec

Cant find what you need?


Try RS online, our guided navigation tools will help you find the product faster
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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

511-1048 511-1032 511-1010

24Vdc DPNO 12Vdc DPNO 24Vac DPNO

$45.40 $45.40 $45.40

hIGh POWER FLOAT SWITChES


General purpose, side mounting switches consisting of a reed switch and pivoted actuator magnet, encapsulated in a waterproof housing.
Can be used for N/O or N/C operation WBS approved for use in hot and cold water Minimum liquid specific gravity 0.8 Supplied with one metre PVC cable

PRE-CAbLED INDUCTIVE SENSORS


Flush mounting sensors in a stainless steel body with a PBT sensing face and two metres of PUR cable.
PNP N/O output 10 to 36Vdc supply Reverse polarity and overload protection Switching current 200mA

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228-1986 228-1992

M12 Nylon body M16 Polypropylene body

$36.70 $40.10

208-184 208-241 208-314

M12 3mm range M18 5mm range M30 10mm range

$75.30 $95.80 $110.00

Rx1A SERIES SOLID STATE RELAYS


Extremely compact industrial solid state relays that are fully pluggable to make installation and servicing so much easier.
Operational range 24 to 265Vac rms, 45 to 65Hz
Page 1798

LED status indication

184-5983 184-5999 218-1915 218-1921 613-8094

25A 3-32Vdc control 50A 3-32Vdc control 25A 90-280Vac control 50A 90-280Vac control MS3 DIN rail mount heatsink

$239.00 $267.00 $208.00 $241.00 $107.00

Screw terminals Suitable for resistive and inductive loads


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535-6364 535-6386

4-32Vdc control 25A 4-32Vdc control 32A

$49.50 $54.90

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AUTOMATION NOVEMbER 08 - MARCh 09 15

hANDTOOLS

The Pliers Company


KNIPEx has been specialising in the development and production of high quality pliers since 1882 and is recognised as Europes leading manufacturer of these products.
Quality for Professionals
Satisfying the highest expectations in terms of performance, ergonomics and service life, KNIPEX products are designed to meet the requirements of professional users, who must be able to rely on their tools.

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.

Section 58, pages 1986 to 1990

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

16 AUTOMATION NOVEMbER 08 - MARCh 09