More Control Automation Solutions Provider

Automation Machine Repair – Torbed 750 Dryer

Posted on April 2, 2012 by more-control

Over the years, More Control has worked on repairing & developing a wide range of different industrial machines and process equipment. Specialising in control systems, machine control, software programming and HMI programming, More Control invests great time and energy into providing high quality machine repair.

Machine Repair: Torbed 750 Dryer

Recently More Control was asked to fix and repair a Torbed 750 automatic batch processor machine which had recently broken down.

Torbed 750 Dryer The concept of a Torbed is to develop a gently rotating bed of material which is continually mixing with hot air passing through the bed. This concept increases the heat transfer rate in the process creating an all round homogeneous treatment of product. The Torbed provides an ideal method of processing particles of any shape in a gas stream (which is normally hot air). A well defined fluidised packed bed of raw material is floated over blades and supported by the momentum of linear jets of process air. The arrangement of blades guides the air flow process at an angle to create a continuous horizontal motion of the bed. This motion creates an evenly developed bed of material which is heated and prepared, ideal for the food industry.

This simple yet effective process increase heat transfer rates and processes particles of any shape in a gas stream. Inside the Torbed 750 Dryer Machine is an integrated system containing a C200H & CS1 PLC, a NT21-ST121 HMI with an Omron 3G3IV inverter. More Control was requested to re-fit, repair and re-programme software to meet its end user requirements of the Torbed 750 dryer.

Having specialised knowledge in software support, More Control was able to provide on-going support to calibrate the machine across a range of flow rates and particles used. As a premier partner of Omron, More Control has access to the complete range of parts needed to repair the Torbed 750 dryer at a very cost effective means.

If you have a Torbed machine which needs repairing or any other automated machine, contact More Control and will support you each step of the way to minimise downtime & improve overall machine efficiency.

Posted in Applications, Automation | Tagged automation repair, machine repair, torbed | Leave a comment

Moeller RF Push Button Switch (Remote Universal Switch)

Posted on March 28, 2012 by more-control

Moeller RF Push Button Switch (Remote Universal Switch)

The Moeller Eaton (X-Comfort) system sets a new benchmark in the field of wireless technology. A universal system for all requirements which controls coordinates and optimises all possible function for end users. With over 30 frame designs offered by leading switch manufacturers, the switches standard 55 x 55mm dimensions make it highly adaptable and superbly functional.

The Moeller (X-Comfort) switches can be obtained in single, double and in a 4 button variation. All rocker buttons are optionally offered with and without LED functions.

The functional LED indicates by blinking whether a sent RF command has actually been received.

The colour schemes of the rocker buttons and switches satisfy both modern living standards and the desire for timeless design.

With the rockers button four different colour variation in white, cream, silver and anthracite it is possible create countless combinations together with the frame design to be tailored to end user requirements.

The RF switches can be mounted anywhere and can be glued to and removed form the walls or from any other desired surface without great effort.

Moeller RF Push Button Switch

When pressed, the single push-button sends signals to the actuators of the electrical installation system. No distinction is required between a shutter, dimmer etc or a two-way intermediate or shutter/blind switch.

The (CTAA-04/04-LED) device is powered by a coin cell. It can be conveniently attached (screw mounted or glued) wherever needed. Thanks to the very flat design, NO switch, branch off or installation box is required.

Installation made easy

Step 1: Mount the base plate
Step 2: Affix of the frame
Step 3: Click-in the switch‘s wireless module
Step 4: Affix the rocker button to the wireless module Simply screw on or glue on

To allow for easy installation, the Moeller RF Push Switch units offers screw bores as well as sufficient surface space on its rear side to attach adhesive strips. The battery integrated in the remote switch has a lifetime of approximately 10 years and can also be exchanged, if needed.

If you would like more information about the Moeller RF Push button and any other Moeller X Comfort items, contact us on 0345 00 00 400.

Posted in Applications, Lighting | Tagged moeller x comfort, rf push button, x comfort | Leave a comment

Production Line Monitoring System

Posted on March 20, 2012 by more-control

In any manufacturing industry, investment on machinery is significant.

To ensure accurate operations in modern industry the implementation of a Production Line Monitoring System allows operators to communicate production parameters to a central system; to record those parameters and use them for generating reports for better managing facilities.

At its core, a production line monitoring system facilitates the need to remotely monitor what is happening on a factory floor and whether the lines are running, running slowly or stopped. Real time monitoring enables supervisors to see at a glance the status of the factory and what might need addressing. This is backed by a number of reports which breakdown and analyse the data captured and then present the information in a simple and straight forward manner allowing managers to take quick and targeted actions.

In essence a production line monitoring system contains two elements.

1. A unit is attached to the machine to monitor inputs and outputs. This unit then communicates this data to the server which records the information in a database. This unit also incorporate a bar code scanner for the operators to use, enabling them to scan standards into the system.

2. The web based application which has the reports and status screen on it.

Information Screen from Production Line Monitoring System

The status screen serves as an instant view of the status of all lines in the factory. The status can easily be seen from the colour of the box. Typically, Red means that the lines has stopped, Amber signifies that the line is running slowly and Green means that it is running within expected speeds.

Information Acquired:

Line: A unique name to identify the line
Work order: this would be the work order the user has scanned the bar code of
Operator: current operator of the line
Part Number: the unique reference of the object being made, which is derived from the work order
Part description: A description of the part being made
Line Status: A description of the current status of the line
Last Sop Reason: This will show the allocated reason code for the last time the line stopped
Target Cycle: this is the number of seconds each cycle of the line is expected to take in seconds
Average cycle: The number of units to be made for this work order
Units Made: Current number of units already made
Auto/Manual: Whether the line is running normally or whether it is in manual override mode
Estimated Complete: The Time this work order is expected to complete based on target units, units made and average cycle time
Last Updated: The last time that data was received from the unit for that line
Message: At Certain times messages can be displayed according to the status of the line.

Benefits of A Production Line Monitoring System

Helps maintain the quality of a manufactured product by recording the rejected quantity. The production line monitoring system captures a machines status in real time from production units. The information about machine down is made available to the operator through audio visual alarms.

- Reduce the rejection of finished products

- Increase machine efficiency

- Optimise Uptime / Minimize Downtime

A Production Line Monitoring System is a complete solution of maintaining the quality of a product and the effective use of a machines time. A Production Line Monitoring System provides accurate and timely information on the real causes of downtime to optimise factory output.

The production line monitoring system frees up operators to do more value added work and production target initiatives to improve overall factory/ production performance.

If you wish to have a production line monitoring system developed in your factory, contact us on 0345 00 00 400 and we can design and implement the right monitoring solution for your company.

Posted in Applications, Automation | Tagged automation, automation solution, production line, production line monitoring solutions | Leave a comment

Energy Saving Technology – School Lighting Control

Posted on March 19, 2012 by more-control

Customer requested to look into reducing their energy consumption in their school. Frequently, teacher & pupils would leave the lights on in classrooms when not in use.

The School building is classified as a “listed building” and did not wish to have any new cables installed throughout to automate their lighting system. Furthermore, cables would be unsightly and expensive to install to go into the conduits.

Moeller X Comfort Lighting Control – Warehouse Light Control

Posted on March 16, 2012 by more-control

Application details:

Customer wished to have an innovative means of managing the light levels in their warehouse to switch on and off depending upon location / machine use in their warehouse.

When a set point triggers or machine device is activated in the warehouse the warehouse will automatically switch on/off light points. For instance when a machine is activated or operating process is completed, the switching actuators would switch on/off based upon the user specifications.

Also the customer requested to save on energy costs by dimming and reducing light levels to get the most out of daylight harvesting.

Innovative Automatic Tablet Counting Machine

Posted on March 14, 2012 by more-control

In the field of Pharmacy Automation constant developments in technology make the dispensing of prescriptions, tablets and medical equipment more accurate and more efficient. Modern machines are required to provide complete accuracy for detecting and dispensing pharmaceutical based products.

To see this application in action, visit the following link:
Automated Counting Machine

To this end, More Control were asked to develop an automatic tablet counting machine which could dispense high levels of tablets / pills and be easily programmed, adjusted and integrated into a fully automated production line.

Application Details:

Automated Tablet Counting
Working alongside a leading UK manufacturer for Pill Counting, More Control was asked to develop the control mechanisms and write / programme the software for their Automatic Tablet Counting Machines.

Integrating a range of innovative Omron PLC’s, drives & latest Omron safety equipment, More Control was able to create a cost effective, accurate fully Automatic Tablet Counting Machine for medium scale counting operations. A key feature of this project was the functionality of this machine over a wide range of tablet types and the ease of operation.

The Tablet Counting Machine is operated and programmed via the use of a HMI touch screen control.

Main Product Features:
• Maximum output of 4000 tablets per minute
• 4.6” vertical touch screen capable of storing up to 50 recipes
• Counts coated and uncoated tablets, hard and soft gelatine capsules and dragees
• Can be integrated into a fully automated production line
• Accurate dispensing with excellent repeatability
• Simple operation with fast product change over
• Tool free removable product contact parts
• Motorised head lift
• Dual lane AUU 0001 unscrambling machine included as standard
• Integrated fault / alarms
• Dust extraction point
• Suitable for pill counting and capsule counting

If you have a Tablet Counting Application which needs designing, contact us on 0345 00 00 400 and our technical engineers can provide an ideal counting application solution for you.

Posted in Applications | Leave a comment

Omron CP1L Micro PLC Control

Posted on February 29, 2012 by more-control

A standard Package Type PLC (All in One Control System)

Omron CP1L Micro PLC Complete with a standard feature USB port, the Omron CP1L PLC’s include CPU units for applications with as few as 10 points. From simple sequence control or pulse I/O and a serial port, the CP1L PLCs give users an economical choice from among 10, 14, 20, 30, 40 and 60 point CPU units. The Omron CP1L PLC offers a wide variety of built in functions, expanding application capabilities and shortening design times required for a growing number of increasingly complex machine control needs.

With the introduction of the Omron CP1L, users can enjoy the benefits of a smart platform technology even in the basic ranges, at an affordable cost.

The Omron CP1L supports mathematical and PID instructions whereby the PLC can be used from simple to complex applications. The Omron CP1L share the same common architecture with other ranges of PLC’s which means that programs written can be migrated over without any modifications.

Main Features:

4 high-speed inputs and 2 *high-speed pulse outputs (*Transistor Models Only)
AC or DC supply and 10, 14, 20, 30, 40 & 60 I/O
Built-in USB port.
Expandable up to 180 points

Network Capabilities with Serial Communications

With the Omron CP1L, Data sharing between PLCs can be achieved using the serial PLC link by connecting in series with RS 485/RS 422 configurations. Communication with other devices such as Inverters and Analog Meter can also be done as seen in the diagram.

The Omron CP1L provides users with the option of three programming languages: Function Blocks, Ladder Diagram and Structure Text which helps reduce development and troubleshooting times.

The Omron CP1L series provides built in USB connections for easier communication. Suitable for users without serial communication ports on their laptops.

Easy Maintenance and Startup Adjustments with LCD Displays and Settings

Attach an LCD Option Board to the CPU Unit to easily monitor or change data values in the CP1L PLC to visually check error status.

Motion Control with Precise Accuracy

Omron Micro PLC CP1L

Pulse Output

The CP1L series comes with two-axis pulse output control at 100khz (max). The CP1L supports a full range of functions for motion control such as Origin Search Function, Trapezoidal Acceleration and Deceleration etc.

High-speed Counter

A maximum of the four-axis counter of Single phase inputs are supported. Two-axis for Differential phase input. In additional, interrupt inputs are also provided.

ModBus RTU

The Omron CP1L with the optional Serial communication port, support Modbus-RTU communication without any programming.

Increased Numbers of I/Os and Memory Capacities

With a wide range of selections for the Omron CP1L, Users can choose the PLC which suits their application. (Expansion options are also available for different models.)

Network Capabilities with Serial Communications

Data sharing between CP1L PLCs can be achieved using a serial PLC link by connecting in series with RS 485/RS 422 configurations. Communication with other devices such as Inverters and Analogue Meters can also be done.

Omron CP1L Micro PLC

Optional Boards

Two types of communications are available.
Either two RS-232C ports , two RS-422A/485 ports or two Ethernet ports can be used.

CP1L-L

I/O Size : 10
Program capacity: 5 K steps
Execution speed: 0.55 µs

CP1L-L

I/O Size : 14 or 20
Program capacity: 5 K steps
Execution speed: 0.55 µs
No of Expansion Unit : 1

CP1L-M

I/O Size : 30, 40, 60
Program capacity: 10 K steps
Execution speed: 0.55 µs
No of Expansion Unit : 3

Omron CP1L Micro PLC Summary

With the Omron CP1L users get all the functionality and flexibility needed in a compact machine controller unit, plus the added advantage of one single platform, which means no worries about field-buses or integration of software.

The Omron CP1L is fully scaleable, has faster processing speeds than other controllers and is in a class of its own when it comes to price and performance.

For more information about the Omron CP1L Micro PLC & other control systems contact More Control on: 0345 00 00 400.

Posted in Automation, Omron | Leave a comment

Omron CP1E Micro PLC (Programmable Controller)

Posted on February 29, 2012 by more-control

Economical, Easy and Efficient Package PLC for Small Scale Systems

The Omron CP1E PLC is designed to meet the wide range of needs of manufacturers requiring high performance and advanced functionality at an economical price.
Omron Micro PLC CP1E
Main Features / Benefits:

Easy Ladder Programming with Smart input
Connect with USB cable
Status easily visible

Advanced Functions:

Analogue Control
Ethernet
Pulse output
Modbus-RTU
High speed counter
Serial PLC Links
Optional Units

The Omron CP1E delivers an exceptional control solutions for automating small machines with a few 20 I/O points and flexibility to expand to 160 I/O. All CP1E, CPU’s offer high speed USB connection for easy connection and “Easy Input Editor” for faster programming by using an intuitive predictive ladder editor.

The Omron CP1E comes in two different products families: CP1E-E is an economical yet powerful model, while the CP1E-N has a built in real time clock, motion control capabilities and an intelligent RS-232 port for connection to an HMI, bar code reader, robot or other serial devices.

As the Omron CP1E series shares the same architecture as the Omron CP1L, CP1H, CJ1 and CS1 programmable controller series, but with a smaller yet powerful instruction set, programs are compatible across platforms and allow for easy upward migration.

The Omron CP1E support complete programming via the CX-One Software, which features easy program developments as well as on-line editing of program logic.

The Omron CP1E models are available with 20, 30 or 40 I/O built-in. The 30 and 40 point CPU’s can be further expanded with a wide range of CP1W expansion units of up to I/O points.

All CP1E-N transistor output models support positioning and motion control with four high speed encoder inputs (100 kHz) for counter which use two-axis differential phase control or four axes of single phase control and two high speed pulse outputs (100 kHz) for two axis control.

The CP1E-N has a built in RS-232 port and offers an additional optional port using a plug in adapter or Ethernet, RS-232 or RS-422A/485 serial communication.

More Applications with Advanced Control Capabilities and Functionality (N-/NA-type only)

The Omron CP1E N/NA-type CPU Units are equipped with high-speed counters, pulse outputs, and a built-in serial port. An option board for an additional Serial or Ethernet communication port is available. These features enable controlling a wide range of devices.

Omron CP1E Micro PLC

Optional Units for More Flexibility

Three expansion units are available. An option board for an additional Serial or Ethernet communication port can be added to N/NA-type CPU unit.

Omron Micro PLC CP1E

For more information about the Omron CP1E Micro PLC & other control systems contact More Control on: 0345 00 00 400.

Posted in Automation, Omron | Tagged cp1e micro plc, omron, omron cp1e, omron plc | Leave a comment

Basic Parameter Set-Up Guide for MX2 Inverter Drives

Posted on February 27, 2012 by more-control

MX2 Inverter Drive Guide

Initialize
Parameter b084 is used to Initialize the drive back to factory defaults:-
b084= 01 Clears Trip History
02 Initialize All Parameters
03 Clears Trip History & Initialize All Parameters
04 Clears Trip History & Initialize All Parameters + EzSQ

Initial Value Select (Country Code)

b085 = 00 Area A (Asia/America/China)
01 Area B (Europe)

Initialization Trigger

b180 = 00 Disabled
01 Perform Initialize

Control Method

The drives control method is set in parameter A044

A044 = 00 Constant Torque V/F (Default)
01 Reduced Torque V/F
02 Free V/F (Set in b100 – b113)
03 Sensorless Vector SLV (Open Loop Vector)

b049 is the setting of the Drive’s Dual Rating
b049 = 00 Heavy Duty Mode (Default)
01 Normal Duty Mode

Reference & Run Command Source
Parameter A001 sets where the reference comes from:-

A001 = 00 Keypad (Pot on external operator)
01 Control Terminals (Default)
02 Function F001 setting (Digital Reference)
03 Modbus network I/P
04 Option Card
06 Pulse Train Input
07 Via EzSQ
10 Calc from Function I/P

Parameter A002 sets where the run command comes from:-

A002 =01 Control Terminals (Default)
02 Operator
03 Modbus
04 Option Card

Ramps
Parameter F002 sets the Acceleration1 time in seconds
Parameter F003 sets the Deceleration1 time in seconds

Basic Start-Up Setup
A003 = Base Frequency (Motor rated Frequency)
A004 = MAX Frequency (FMAX)
A082 = AVR Voltage (Automatic Voltage Regulator), Motor Voltage, this setting is in fixed steps.
B012 = Electronic Thermal Protection (Motor Rated Current)
B082 = Minimum output Frequency (FMIN)

Fixed References
Parameters A020 to A035, are where Internal Multi-Step Reference frequencies are stored

Overall Frequency Limits
A061 = Upper Freq Limit
A062 = Lower Freq Limit

Digital Input Terminals
Parameters C001 to C007, used to set the functionality of the Digital Inputs1 to 7.

Parameter InputTerminal (Default Setting)

C001                       1                                    00               (Forward)
C002                       2                                    01       (Reverse)
C003                       3    12        (External Trip)
C004                      4                                     18           (Drive Reset)
C005                      5                                     02       (Multi-step Bit0)
C006                      6                                     03         (Multi-step Bit1)
C007                      7                                     06                        (Jog)

Digital Output Terminals

Parameters C021, C022 & C026, used to set the functionality of the Digital Outputs 11,12 & Relay AL0, AL1 & AL2

Parameter Output Terminal (Default Setting)
C021                  11                             00               (Run Signal)
C022                  12 01               (Freq Arrival)
C026               Relay                          05               (Alarm)

Analog I/O Scaling Based on A004 MAX Freq
Analog input “O” Voltage
A012 = Upper Frequency Scaling in Hz
A011 = Lower Frequency Scaling in Hz
Analog Input “OI” Current
A102 = Upper Frequency Scaling in Hz
A101 = Lower Frequency Scaling in Hz

Analog Output “AM” Function Set in C028
C106 = Gain % (100 = Default)
C109 = Offset % (0 = Default)

Auto-Tuning Function
Motor Data
The following parameters are used to set-up the basic motor data:-

A003 = Motor Base Frequency (Default = 50Hz)
A082 = AVR Voltage (Automatic Voltage Regulator) [Motor Volts set in Steps]
b012 = Motors rated current in amps
H003 = Motor Capacity in Kw
H004 = No of Motor Poles

Auto-Tune Function
Selects the type of Auto-tune operation:-
H001 = 00 Disabled
01 Static Tune
02 Rotational Tune

Auto-Tune Usage
This parameter selects which motor data is used:-
H002 = 00 Hitachi Standard Motor Data
02 Auto-tuned Data

Auto-tuned Data
The Auto-tuned data is stored in the following parameters, used with H002 = 02:-

H030 = R1 Motor Constant R1 (Ohms) Resistance
H031 = R2 Motor Constant R2 (Ohms) Resistance
H032 = L Motor Constant L (mH) Inductance
H034 = IO Motor Constant IO (Amps) Current
H035 = J Motor Constant J (kgm2) Inertia

Carrier Frequency
The following parameters are used to set the carrier frequency functions:-

b083 = Carrier Frequency (KHz)
b089 = Carrier Frequency Reduction
00 = Disabled
01 = Enabled dependent on output current (def)
02 = Enabled depends on heatsink temp

Useful Functions and monitoring

Monitors

F001 = Reference Frequency in Hz
F002 = Accel Time1 in Seconds
F003 = Decel Time1 in Seconds
d001 = Output Frequency Hz
d002 = Output Current in Amps
d003 = Rotation Direction F/R
d004 = Process Variable (PV), PID Feedback

d005 = 1 to 7 Input Terminal Status (Independent of Programming)

Omron MX2 Inverter Drive

See below diagram for explanation:-

d006 = Digital Output Terminal Status of 11,12 and AL2/AL1/AL0 relay terminals (Output Function set in C021,C022 & C026 Parameters)

See below diagram for explanation:-

Common Alarm Codes

There are several common alarm codes which occur on a more frequent basis, below is an explanation of a few:-

E05: Motor Thermal Overload
This alarm is based around the motors rated current set in parameter
b012.
The drive monitors the current being drawn by the motor and makes a calculation of how long and how much current the motor is drawing in the peak region above the setting in b012 during Acceleration and Running.
The drive also calculates the time spent running a motor at low output frequencies, as the cooling fan built into the rear of standard induction motors has little or no cooling effect in a motor running at low speed, thus the motor has a possibility of failure due to over heating.

E01 to E04: Over Current
The cause of this alarm is normally due to some form of short circuit on the output of the drive.
With the motor disconnected, run the drive and if this alarm still occurs it’s likely the output transistors have gone short circuit, thus the drive will need repairing or replacement.
If this fault is not present with the motor disconnected, it’s likely the fault lies with the motor, either the windings are shorting to earth or between phases.
In either case the motor should always be Checked / Tested thoroughly.

E07: DC Bus Overvolt
Generally this alarm only occurs for 2 reasons:-
1. The incoming mains supply to the drive is very high, causing the DC bus voltage to rise above the trip level, usually shown as E15 alarm.
2. During motor deceleration, energy is regenerated from the motor back onto the DC bus of the drive causing the DC Bus Voltage level to Rise up to the internal trip level of the drive.
This can be due to a large inertial load or if the drive has been fitted with regenerative resistors and they have gone open circuit.

E21: Inverter Thermal Trip

Heatsink Overtemp /Heatsink Max Temp, occurs when the drive’s ambient temperature is too high or the cooling fans have become blocked with dirt build-up, these alarms will occur.

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Moeller X-Comfort RF Radiator Valve

Posted on February 20, 2012 by more-control

The Moeller RF Radiator Valve (CHVZ-01/03) is ideally used to control standard radiator valves in both residential and office use applications.

Moeller X-Comfort Radiator Valve The Moeller RF Radiator Value controls the room temperature. The drive moves a valve, to control the heat flow of the radiator. The Moeller RF Radiator Valve can be operated as a stand alone application or be in connection with a central device such as the Moeller Room Manager (actuator operation)

The RF Radiator Valve is fully programmable; battery powered which will fit in place of most commonly fitted TRV valves from Honeywell, Danfoss, Screwfit, B & Q, and Wickes.

The Moeller RF Radiator Valve provides complete control of the temperature in a room, depending upon the time of day. This application saves on energy costs by only raising the temperature in a room when the room is in use. The programmable valve allows users to set different temperatures at different times of the day, ensuring maximum energy savings on heating costs.

Main Benefits of Radiator Valve

Clear illuminated display for current temperature, set temperature, valve position, etc
Each room can be regulated separately by means of weekly programming
Can be used in combination with a central control unit or independently
Suitable for M30 x 1.5 connection
Adapter available for M28 x 1.5 m 00 cm coupling / 36

A conventional thermostat can quickly and easily be replaced by a battery powered thermostat and immediately put into use. With a new battery operated radiator valve, Moeller X-Comfort offers innovative solutions when it comes to efficiently heating various rooms.

For advice and guidance on how to setup the Moeller X-Comfort RF Radiator Valve, download the complete datasheet and installation guide here.

Moeller RF Radiator Valve Technical Specifications

Power Supply: 3V via Battery (2x 1,5V Mignon/AA)
Connection: M30 x 1,5
Battery life: approx. 2 years
Frequency: 868,300MHz
Display: LC-Display
Regulation distance: 4,2 mm
Regulation force: max. 80 N
Degree of protection: IP20
Ambient temperature: +5 bis +55°C
Max. surface temperature: +90°C (of the radiator)
Housing colour: similar to RAL9003 (white)
Dimensions of the enclosure: HxWxD – 70 x 63 x 99 mm
Approval: Printed onto the device

For more information on the Moeller X-Comfort RF Radiator Valve contact us for a live demo and find out how much you can save on your heating today!

Posted in Applications, Automation, Control | Tagged moeller, radiator valve, x comfort | 2 Comments