Sponsored By

June 1, 2000

15 Min Read
A Slew of New Control Products

1npelogo4c.jpgA Slew of NewControl Products

Barber-Colman and Eurotherm Controls will introduce a range of new control products at NPE (Booth N-6016). Please contact the companies directly for pricing (see the Key Contact Directory on p 100). Included are:

16.jpgI/O system The Model 2500 input/output system has two PID controllers and is capable of mathematical functions, combination logic and remote analog and digital I/O monitoring. Future expansion to four and eight PID controller versions is planned. Unit also provides adaptive tuning, cascade control and gain scheduling.

The product line consists of a DIN rail mounted base (rack), processor, terminal units, input/output modules and an externally mounted 24 v dc power supply. It is designed to be interfaced with any device running Modbus RTU or Profibus DP master communications, such as Eurotherm Controls' Model T2900 operator interface, PC-based supervisory software packages or a programmable logic controller. Up to 16 bases can be connected in a communications network.

Three base sizes allow for efficient use of space while obtaining the input/output needed. One base can have a maximum of 32 analog and 64 digital inputs and outputs. DIN rail-mounting allows the 2500 to be mounted where the control action is required, minimizing the cost of the enclosures and wiring since only the twisted pair communications cable is taken to the user interface.

Model 2500 is configured using the Eurotherm Controls/Barber-Colman Windows-based configuration software package, iTools (see below). This software is used to set up the PID blocks and to configure the input/output points to the PID blocks or to internal variables. iTools is also used to set up the Toolkit Function Blocks contained in the 2500controller. These blocks allow local mathematical calculations and combination logic.

Highly stable control with a range of control options is available in the 2500. Each PID block offers one-shot and continuously adaptive tuning to optimize control performance. Each PID block can be configured as asingle PID, cascade, ratio or override control loop. A gain-scheduling feature allows the control strategy to automatically switch between three sets of PID terms based on processing conditions.

The 2500 can also be used as expansion remote I/O for the Eurotherm and Barber-Colman Model 2604 (see below) and Model 2704 multi-loop controllers. The master communication feature of these units enables serial digital communications to the Model 2500. This combination of instruments provides a compact and economical system for complete control of small plastics processing machines. 

17.jpgMulti-loop melt pressure controller Model 2604 (1/4 DIN) high-stability pressure controller is a new member of the Series 2000 family of controllers. It is designed for plastic melt pressure applications. Strain gage inputs can be energized from an internal 5- or 10-v dc supply on the 2604. The controller is also equipped with a precision melt pressure control algorithm and includes an automatic calibration routine to remove zero and span offsets.

The 2604 is available with Modbus RTU or PROFIBUS DP slave communications. This controller is ideal for connection to PLC- or PC-based systems in which the security and high accuracy of an independent melt pressure controller is required.

All parameters are available over the communications interface. Configuration is achieved either via the front panel or by using iTools configuration software. Software tools also simplify Profibus GSD file generation and run under the Windows 95, Windows 98 or Windows NT operating systems. 

18.jpgExtrusion control system is designed to save extrusion equipment OEMs time and money. With the EM3 OEMs no longer need to design and manufacture their own control systems to keep routines confidential.

Originally introduced at K'98 as the Maco DS, the system is based on a building block architecture that is designed to adapt to the changing needs of plastics processors. The result is an open and scaleable system that contains more than four decades of extrusion knowledge.

The EM3 is actually a family of control products: the PC-based Operator Station (OPtima PC), Application Specific I/O Blocks (ASBs) and Terminal I/O Blocks (TBs). The OPtima PC, ASBs and TBs can be networked together to form an overall control scheme. It can be applied as a total line system or as individual components.

According to Barber-Colman /Eurotherm, there are many benefits and cost savings associated with the EM3:

  • Labor and materials savings by directly wiring to terminal I/O blocks

  • Fewer failures due to the use of robust hardware

  • Higher productivity from advanced control

  • Scaleability (one control solution for large and small lines)

  • Fast installation (DIN rail mounting)

  • Shared data base between screen programming tool (Wonderware InTouch) and sequence editing tool

  • Global application (unit ismulti-lingual)

  • Flexibility of distributed orcentralized I/O

  • Connectivity to third party devices

  • Small profile to reduce panel space

  • Large color graphical interface for easy use

  • Pre-configured screens and sequence for rapid start ups

  • Efficient sequence programming tool for reduced development cost (on-line editing, diagnostics and simulation)

The OPtima PC human-machine interface (HMI) is packed with 'superior' software and incorporates the Wonderware InTouch Interface. Standard features include multiple windows, on-line documentation, animated objects, statistical process control (SPC), on-line trending and recipe management.

The OPtima PC is housed in an industry-hardened cabinet to minimize the effects of electronic noise. A 233 mHz Pentium processor and a 15-in. active matrix display provide 'super fast' and crisp graphics. Recipes can be stored internally on a hard disk drive or externally on the floppy disk drive.

The OPtima PC comes standard with one serial port, one parallel port and one keyboard port. For greater expansion, three 1/2 length add-in cards can be placed inside. They are compatible with ISA and PCI type cards.

Operators and technicians can access the OPtima PC from anywhere in the world. Connect a modem or local network and view/control the application from a remote site. Or browse a web page for troubleshooting information or material specifications.

Application-Specific Blocks can be configured for any extrusion application. The EM3 uses a distributed control structure that features intelligent I/O modules with on-board microprocessors. In addition to the on-board microprocessors, each Application Specific Block can be populated with a central processor for custom control and local I/O drops. The central processor supports true IEC 1131-3 programming (Ladder Diagram, Function Block Diagram, Sequential Function Chart, Instruction List, Structured Text and Runtime Controller Simulation) for discrete I/O, on-line monitoring/editing and Custom Control Capability.

The custom control capability is said to be unique to the EM3. Through the sequence-programming package, a low-level C++ block can be downloaded to modify or enhance Eurotherm Control/Barber-Colman routines. The six card slots in the Application Specific Block can be populated with temperature, analog or discrete I/O cards.

Application Specific Blocks include an easy-to-use, full-feature temperature controller and a drive and pressure controller.

The temperature controller includes adaptive auto-tuning control, designed to let users quickly bring temperatures to within 1° F. Smart routines watch for process high, low, deviation ±, heater burn-out and thermocouple break alarms. The Automatic Heat Start-Up allows users to enter the time and date, and the controller heats by itself. Advanced users will benefit from the melt temperature control (cascading temperature) and temperature ramping.

Advanced software routines manage digital drive communications, drive speed ratio control, bumpless transfers, ramping and closed-loop melt pressure control.

The EM3 Terminal I/O Blocks comprise four kinds of assemblies, which snap together to form varying automation control elements. Once assembled, these I/O elements can be networked to form a control solution.

Each Terminal I/O Block has a base. A base is comprised of 20 different types of dc, ac and analog I/O configurations. Each base is specifically designed so that it can be wired directly to eliminate the need for intermediate terminal blocks or marshaling strips.

On top of each base rests a slave communication adapter or a processor. When coupled with a slave communication adapter, the two form a remote I/O drop that can be directly connected to the Application Specific Block or to virtually any standard fieldbus I/O network.

When local distributed intelligence is required, a processor can be added on top of the Terminal I/O base. This offers the same processing capability as the Application Specific Block, but without the Application Specific Cards.

A second variation of the processor base combination is available with a master communication adapter, which fits between the processor and the base and provides the processor with additional communication ports.

Replacing and troubleshooting the modules is said to be easy. The terminal connectors snap in and out, and the communication adapter snaps on and off, allowing for the quick change of a base. The processor and slave communication adapter also contain a label for field wiring identification. Just look at the wiring identification, inspect the LED status on the base and touch a digital voltage meter to the accessible screw on the connector. 

19.jpgNew version of Windows-based configuration software, iTools Version 2.3, is a 32-bit program designedfor configuration and cloning of thecompanies' Series 2000 family of PIDcontrollers and indicators. There are three editions of iTools Version 2.3:Demo, Standard and Open. The Demoedition of iTools is available for evaluationfree from the Eurotherm web site (www.eurotherm.com).

The software operates on any PC running Windows 9x or Windows NT and uses Modbus RTU to automatically detect Series 2000 controllers via a PC's serial port. Non-communicating controllerscan use the optional Series 2000 Configuration Station that does not require the controller to be line powered.

iTools includes a Modbus RTU OPC Server (EuroMBus) that provides high-speed data links into other OPC client software. iTools also ships with the Setpoint Programmer Editor (SPE) and OPC Scope. The SPE provides visual programmer generation for Series 2400 programmers from Eurotherm and Barber-Colman. OPC Scope is used to browse any local or remote OPC Server and provides sophisticated trend plot and data logging capability.

Version 2.3 of iTools was released in February 2000. Improvements include support for the new 2604 multi-loop controller, support for the new Model 2500 V2.2 I/O system, OPC Data Access Version 2 interface compliance and a Parameter List ActiveX control in addition to the Replication Front Panel ActiveX Control. 

20.jpgParison programmer Maco DS, a complete blow-molding machine control system with 100-step parison programming for precise, uniform wall thickness in blow-molded products, now offers a Windows based display.

The parison profile shows the product thickness set points and values by positioning a cursor along the profile display. Once programmed and parison points tried, the wall may be found to have thick or thin places. Processors can now use the visual display to locate these spots. As few as two master points can be placed on the screen and five types of interpolation create the profile.

A tabular pop-up window quickly shows the individual point along with the percentage die gap opening of that point. Prove-out time is reduced because the entire parison profile or master points can be shifted in either direction. There is no need to locate a point on the blow-molded part; instead, users just enter a lock point at the minimum or maximum thickness. Profiles can be saved to the hard disk or floppy drive. 

20.jpgTwo families of non-PC based operator stations are now available on the new Maco DS/EM3 plastic control system. Both families are designed to be easy to use and to reduce start-up costs. Every operator station wires and programs the same. Equipment OEMs can lay out and program their machines using a lower cost gray scale display and let their customer upgrade to electro-luminescent or color displays.

All operator stations ship with screens for injection, extrusion or blow molding. Screens can be changed or added to suit customer-specific needs with the OptiGrafix screen editor software. Internal or external Insta-Set job recipe storage is standard. A single cartridge or floppy disk can store multiple recipes. The cartridge or floppy disk can be used to back up or restore screens and/or sequence programs.

On power up, the first screen displayed contains a field to enter a security code. This code allows access only to screens where the security level is equal to or lower than the code entered. Once the security code is entered, the operator can easily page through all of the authorized screens with the six 'path' keys on the display.

Twenty-four machine function buttons can be used in place of hard-wired momentary, toggle and selector switches. Slide-in legends identify each of the individual buttons and their independent LEDs.

The Maco Lite family (Dec '98 PA, p 17) is designed for applications that need a larger screen with more capabilities in a small cabinet. The Lite offers a 7.4-in. gray scale or 6.4-in. color display with 640 x 480 resolution. The display supports fonts, graphics and sprites.

The OPtima is a full-size, full-featured family of operator stations. One cabinet is used for a 10.4-in. 640 x 480 grayscale LCD, active matrix TFT color LCD or an electro-luminescent display. 

20.jpgPID controllers with Profibus communication are new members of the Series 2000 family of controllers. Models 2408f (1/8 DIN) and 2404f (1/4 DIN) are said to offer all the standard features of the Eurotherm Series 2400 controllers, but are now available with Profibus DP slave communications.

Both are available as high-stability PID heating and cooling controllers, valve positioners or setpoint programmer/controllers. They are reportedly ideal for connection to programmable logic controllers or PC-based systems where the security and high accuracy of single-loop PID control is required. All instrument parameters are available over the Profibus communications interface.

The 'ready to run, right out of the box' design of the 2408f and 2404f reduce installation and configuration time. Windows-based software tools simplify Profibus GSD file generation and provide off-line controller configuration and instrument cloning. 

20.jpgNew communications interface, called the REMote I/O or REMIO, is for solid-state contactors.PLC- or PC-based control systems can communicate digitally to the REMIO. The REMIO can control solid-state contactors via the time proportional module(TPO module) or the on-board digital input/output (digital module).

The REMIO can have up to three TPO modules, each capable of controlling 16 independent zones of proportional heating, firing TE10S solid-state contactors. The REMIO can fire the TE10S in burst firing mode for use with low-temperature coefficient loads or intelligent half-cycling mode, for use with high-temperature coefficient loads, such as short wave infrared (SWIR).

Intelligent half-cycling is said to reduce thermal shock to the heating element and to lengthen the life of the element. The REMIO is economical and is designed to eliminate the need for expensive phase-angle-fired SCR power controllers in non-transformer fired applications. Alternately, the REMIO can have up to three digital modules controlling up to 8DI/8DO or 16DO per module.

The REMIO is available with digital communication via Modbus, Profibus DP or DeviceNet. It is said to be a cost-effective solution for such multi-zone-heating applications as die bolt control, thermoformers and infrared dryers. 

20.jpgAdvanced load diagnostics in Series 2000 controllers were developed specifically to enhance safety in demanding temperature control applications and are now a standard feature of the 2200 and 2400 range of PID controllers. Instant detection of solid-state contactor short circuit failures and load open circuit faults, as well as steady visual display of 'on state' current, is provided on the controller display.

An intelligent CT module is used to transmit load current values and fault diagnostic alarms to the controller. Signaling is by means of Eurotherm's patented pulse density signaling (PDS) communication technique and requires no additional wiring to the remote solid state contactor. This technique is said also to eliminate time delays and enables processors to recognize and diagnose fault conditions the moment they occur, thereby minimizing safety risks.

The intelligent CT module is available as an integral option in the EurothermControls/Barber-Colman TE10 range of single-phase solid-state contactors or as an externally mounted product(PD/CTX) foruse with a variety of industrial solid-state contactors and mechanical contactors. 

20.jpgDeviceNet communications have been added to the 2200e Series of PID controllers, which are available in 1/16, 1/8 and 1/4 DIN sizes. The 2216e, 2208e and 2204e controllers support DeviceNet communications and are said to be ideal for connection to aPLC- or PC-based system where high security and accuracy of single-loop control is required.

The DeviceNet implementation supports both Polled I/O Messaging, for high-speed transfer of primary parameters, and Explicit Messaging for programming operating and configuration parameters. The controllers are available with selectable DeviceNet baud rates of 125K, 250K and 500K bits/second.

Standard features include universal inputs with Instant Accuracy, auto and adaptive tuning, power feedback, dedicated fan, water- or oil-cooling algorithms, high noise immunity, UL/cUL and CE approval and comprehensive diagnostics. 

20.jpgAC and dc input options have been added to Series 7 power controllers. These devices are designed to control resistive loads using a 24 v ac, 100/240 v ac or 24 v dc on/off logic output from a temperature controller. They are specifically tuned to ensure quick temperature ramping, precise operating control and immediate temperature stabilization.

The controllers are DIN rail mountable and feature a 'finger safe' design and on/off zero cross switching in 400 Vrms and 600 Vrms ratings. The Series 7 is available in 15 through 80 amp ratings, single- or three-phase models. All models carry the CE mark.

Series 7 units are also said to be a cost-effective solution to environmentally unfriendly mercury contactors in extruder barrel control, die bolt control, blow molding and injection molding.  Barber-Colman Co./Eurotherm Controls Inc.
Reston, VA

Sign up for the PlasticsToday NewsFeed newsletter.

You May Also Like