Energy Plant Solutions Reduces Boiler Control Cost & Development Time with the Vision1040™

Energy Plant Solutions of Palmerston North, New Zealand needed a cost effective automation solution for their range of package boilers. The Vision1040™ met all their needs and stayed within their budget. “Working with the Unitronics combined PLC and HMI make other systems feel old fashioned and obsolete.” – Justin Butler, Senior Electrical Engineer at Energy Plant Solutions.WHY THE VISION1040™? The V1040 provided the right balance of screen size and number of physical buttons as well as communication ports.

WHY THE VISION1040™? The V1040 provided the right balance of screen size and number of physical buttons as well as communication ports. Because they were using the EX-A2X along with (2) IO-DI16, (2) IO-RO16, (2) IO-AI8 and (2) IO-AO6X’s, (Giving a total of 32 digital inputs, 32 relay outputs, 16 analogue inputs with 14 bit resolution and 12 analogue outputs with 12 bit resolution all neatly DIN rail mounted) the large screen allowed ample room to display the required information while keeping the fonts and elements large enough for easy reading. The physical buttons allowed them to have most buttons always available without using up any of the screen. This also helped with keeping the screen clean.

“There were significant cost savings using the Unitronics PLC,” said Justin Butler, Senior Electrical Engineer at Energy Plant Solutions. “This is for both the development software licensing (it doesn’t get much cheaper than free) and also in the time required to develop the PLC/HMI software. Making changes is so much quicker when you can add the necessary logic to the PLC program and then immediately add the new elements to the HMI without having to export or import tag data, etc.

Also if we need to move some operands we can do it in a single step and the changes are made to the PLC and HMI code immediately.” Butler goes on to say, “With Remote Operator, we can see exactly what the operator sees from our office at the other end of the country via a VPN at absolutely no cost either financially or in development time. This is a huge advantage if the client requires assistance to solve a problem. Because the PLC and I/O modules are all 24VDC, we were able to use a 24VDC uninterruptible power supply (“UPS”) to maintain power to the PLC and I/O on power failure. Because the “UPS” does not need to step the power up to 230VAC before being stepped back down again, we achieve maximum up time afforded by the batteries. It is also safer because there is no 230VAC present when the main power supply is disconnected.”

The SMS system sends the operator an actual description of the fault, rather than just a generic “boiler fault” message. This allows the operator to make a decision on how quickly he needs to attend to the fault. The fault messages on the HMI and SMS are the same and come from the string library- therefore, they do not need to be coded twice.

“Unitronics PLCs allow us to run the PLC without any I/O attached. This is great for testing before the system is deployed on site,” says Butler. “This works like a simulation where we can enter any values we like for conditions and test that the PLC acts as intended. We can also check that all the graphics work and look good on the actual screen that will be used. This means we can do 90% of the testing before we even go to the site.”

“Working with the Unitronics combined PLC and HMI make other systems feel old fashioned and obsolete,” says Butler. “The support from Unitronics, from our local supplier, to email support, to help ideas on the forum, has been absolutely fantastic.”

For more information http://www.unitronics.com/Content.aspx?page=ApplicationStory “Boilers” section: “Energy Plant Solutions-Package Boilers”

Introducing Our New 2011 Products!

Introducing Our New 2011 Products!

NEW V130-33-TR20 replacing V130-33-R2

NEW V130-33-TR6 replacing V130-33-R6

NEW V200-18-E62B

NEW IO-AI8

NEW EX-A2X replacing EX-A1

NEW V130-33-TR20 replacing V130-33-R2

With the addition of 2, faster than ever high-speed PTO outputs, these enhanced units will be REPLACING the V130-33-R2 and V130-33-R6 units and still remain the SAME LOW COST!

V130-33-TR20 V130-33-R2(To be discontinued)
Inputs
Digital pnp/npn 12 12
HSC/Shaft –Encoder/Max. Freq. Measure 3 x 200kHz32-bit 3 x 30kHz32-bit
Analogue 2 x 10-bit, 0-10V,0-20mA, 4-20mA 2 x 10-bit, 0-10V,0-20mA, 4-20mA
Outputs
Digital 6 x Relay 6 x Relay
High-SpeedOutputs/PWM 2 x npn (2PTO)200kHz max None

More functionality for the same price

NEW V130-33-TR6 replacing V130-33-R6

With the addition of 2, faster than ever high-speed PTO outputs, these enhanced units will be REPLACING the V130-33-R2 and V130-33-R6 units and still remain the SAME LOW COST!


V130-33-TR6 V130-33-R6(To be discontinued)
Inputs
Digital pnp/npn 8 6
HSC/Shaft –Encoder/Max. Freq. Measure 2 x 200kHz32-bit 1 x 30khz32-bit
Analogue 6 x 10-bit, 2 x 0-10V,4 x 0-20mA, 4-20mA 6 x 10-bit, 2 x 0-10V,4 x 0-20mA, 4-20mA
Outputs
Digital 6 x Relay 6 x Relay
High-SpeedOutputs/PWM 2 x npn (2PTO)200kHz max None
More functionality for the same price!

The Advantage is clear:

At the SAME LOW COST as the previous R2 and R6 models, these new, High-speed “TR” models can handle inputs up to 200 kHz while high-speed outputs are able to support 5Hz to 200 kHz. In addition to all the core features of the previous R2 and R6 models, these new “TR” models enable the user to implement up to 2 independent Pulse Train Output instruction sets at one time for accurate Step-motor control. Providing flexibility when configuring a system’s precise requirements, these new High-speed I/Os offer particular benefits to the motion industry, or wherever speed control is required.

NEW V200-18-E62B

More I/O than Ever!

This new snap-in I/O module is equipped with 62 I/Os!

V200-18-E62B
Digital Inputs(isolated) 30 npn/pnp (including2 shaft-encoder inputs)
Analogue Inputs 2  x 10-bit0-10V, 0-20mA

4-20mA

Digital Outputs

(isolated)

28 x pnp2 x npn/pnp

High-Speed

What Are the Advantages of More I/O?

Specifically, the E62B snap-in module can be promoted where budget is a primary factor. Being equipped with more I/O allows this snap-in module to help cut costs by taking the place of expansion modules and adapters that may have otherwise been purchased.

NEW IO-AI8

IO- AI8 IO-ATC8
8 Analogue Inputs 8 Thermocouple/ Analogue Inputs
0-10V, 0-20mA 14-bit T/C J,K, T, B, E, N, R, S, 0.1˚ Resolution,0-10V, 0-20mA, 4-20mA, 12/14-bit
A low cost alternative!

The EX-A1

local I/O expansion adapter has also been upgraded and will soon be replaced with the NEW EX-A2X

local I/O expansion adapter with an isolated communication port.

For the SAME LOW COST, now with a cable length of up to 20 meters (versus

A 1 meter cable with the EX-A1) the EX-A2X is able to significantly reduce electrical noise in the field.

EX-A2X EX-A1(To be discontinued)
Local I/O module adapter Local I/O module adapter
Galvanic isolation 20 meters max 1 meter max
Up to 8 modules may be connected to a single PLC Up to 8 modules may be connected to a single PLC
Supports both 12/24 VDC Supports both 12/24 VDC
Same price greater functionality

Remember:

• The compatible cables for this unit are the “XL” type (EXL-CABXXX).

• *Note: The “EX1-CAXXX” cables cannot be used with the new model!

• The “EX XL” modules with the built in expansion port also use this updated isolated port and “XL” cables. (EX-D16A3-RO8 and EX-D16A3-TO16)