The temperature in is accomplished by using the F2-04THM Thermocouple input
option card.

The analog in is a 4-20ma type option card. The F2-08AD-1 is a 8 channel 4-20ma 12Bit
option card.

The Ethernet connection is done by using the H2-ECOM module

This incorporates Automation Direct's 24 Volt D.C. Din rail mount Power supplies.

Supply list

Automation Direct.
P.L.C.
.Motor Starter
Touchscreen (Not Shown)
All Terminal Blocks, Fuse Blocks and Din Rail.
Older style Din Rail mounted 24VDC Supply.
Wire Ferrules and lugs
Back Panel (White panel everythings on)
Enclosure (Not shown which is Stainless Steel)

Allied Electronics.
Circuit Breakers (Now available at Automation Direct)
EMI Filter
Wire way and covers.
Wire
Fuses

About this System

This control system was first electrically designed by me to get the basic electrical systems required.
I then drew up the first electrical prints using Autocad 2000i. After that I laid out the panel, again using
Autocad, with 1:1 scale drawings of the parts. This allows me to move things around and find the best fit
and logical layout before any parts are even ordered.

After the layout drawings are completed to my satisfaction I order the parts from my suppliers.

So What does it do?

This controls a 2 temperature dependant process via the thermocouple card. The P.L.C. uses its P.I.D. control
to control these 2 temperatures. The resulting temperature control switches on and off the 2, 40A Solid State
Relays on the panel (2 Light blue devices center left). These SSR's feed 240 Volts to 2 heater bands.
The other 2 temperature inputs monitor a process chamber and cooling water temperatures.

The 8, 4-20ma analog inputs monitor 3 process pressures. These Pressures are converted by pressure to 4-20ma
transmitters with ranges from 0-100PSI to 0-500PSI. The 4th thru 8th input is unused.

The P.L.C. Is connected to an EZ-TOUCH color touch screen.
This screen lets the operator key in operating parameters and displays the running status of the machine.
It includes all Start and Stop "Switches", except power on and off and E-Stop.

The P.L.C. controls a water pump via its outputs which are connected to a din-rail mounted relay
by Wago. This provides isolation from the control power A.C.
This isolation increases the stability and durability of the process by protecting the P.L.C. from switching
spikes and power fluctuations. The relay, in turn, turns on and off a Cutler Hammer
Motor starter purchased from Automation Direct as well.

Motion of the process is done using 2 Nema 23 sized servo motors from QuickSilver Controls
The Silvermax brand of servo motors
The servomotors are controlled by the P.L.C. by serial communication via the F2-CP128 coprocessor.
The speed, direction, start and stop are "printed" out of one of the F2-CP128's communication ports in RS485.
This simplifies the control system of the Servo motor to a 2 wire communication cable. Power is supplied by a 48 Volt
10Amp D.C. power supply (Lower right, Large silver box). This is manufactured by Mean Well and has an automatic
cooling fan that comes on only when the power supply needs it to. The Power supplies main power is fed by the
E-stop which kills power to the 48VDC supply as well as all outputs. The P.L.C. stays operational to control the logic
and prepare the machine for operational status when the E-Stop is reset.

The P.L.C. is programmed to display maintenance information and statistics on the touchscreen.
These allow maintenance personel to look at information. The P.L.C. has a EMI filter to protect the unit from spikes
and surges (Can below P.L.C.).

All operational parameters and realtime run data can be monitored at a remote location by using the H2-ECOM module
that is plugged into the P.L.C. This also allows easy software updates and diagnostics right over the network, No need
to haul the Laptop down to the machine. Realtime monitoring and collection is done by using Lookout Direct or
DS Data Server supplied by Automation Direct.