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Power SuPPlieS
A look into the products, technologies And solutions shAping the mArket
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MACHINE DESIGN • SYSTEMS • TECHNOLOGY
Technology handbook
Power Supplies
Making dollars and sense: Connectors more popular than ever
F
ew industrial innovations have weathered the years as well as rectangular connectors. Invented by Wilhelm Harting in 1950, rectangular connectors are in greater use than ever, an indispensible part of machine and plant design. The HARTING Technology Group, still owned and managed by Harting’s descendants, is the world leader in heavy duty industrial connectivity. Equipment manufacturers continue to switch from point-to-point (hard) wiring to connectorbased cable assemblies to improve their unit costs and productivity. Switching is particularly compelling where electrical connections are undone and redone after fabrication, be it to transport and assemble the machine in the field, or for maintenance. Disconnecting and reconnecting hard-wiring is labor intensive and expensive while connectors are basically plug and play. Connector-based cable assemblies can be pre-assembled and pre-tested, saving on materials and reducing the risk of wiring errors once the machine is ready for testing. They take up less space inside the machine, giving designers more flexibility. Most rectangular connectors are modular and user-configurable. HARTING launched the concept of user-defined modularity in the early 1990s with its Han-Modular® system that allows each customer to assemble a custom connector with stock catalogue components. HanModular® has catered to modular machine design and helped popularize it. Different transmission media and contact types – power, signal, D-Sub, coaxial, fiber optic, pneumatic or combinations thereof – can be combined in a Han-Modular® housing to create a high-performance, power or multi-purpose interface optimized for the specific application. One Han-Modular® unit can fit power inserts up to 200 Amps or 5000 volts as well as inserts for pneumatic, data, shielded bus signals and POF or glass fibre optical. Many of HARTING’s other proven connector series offer similar options in user-configurability, often by incorporating some of the more than 40 Han-Modular® inserts. HARTING innovations like Han-Quick Lock® termination and click-and-mate assembly make factory or field
2 MA • Technology Handbook Power Supplies
installation as well as maintenance faster and simpler than ever. HARTING connectors offer unrivalled reliability. They are available in different sizes, and come in a range of coated and uncoated metals and plastic, with different cable entry angles, termination and latching options. There are slim models to fit compact units or tight spaces and specialty versions in standard sizes optimized for high heat or corrosive operating conditions, high mating cycles, harsh environments (requiring a IP68/69K rating), high current-carrying applications or where extra EMC shielding is required.
Han-Eco® is one of HARTING’s newest heavy-duty industrial connector series. It’s the user-configurable, modular connector with lower weight and price than metal, thanks to its rugged thermoplastic hoods and housings.
ABOUT Company name: HARTING Technology Group Headquarters: Espelkamp, Germany Employees: More than 3,800 worldwide Global reach: Subsidiaries in 40 countries, production facilities in Europe, Asia and North America Turnover: €484 million Core business: Intelligent and high-performance connectivity for plant engineering, factory automation, power generation and distribution as well as industrial networks and telecommunications. Products: Electrical and electronic connectors, device terminations, backplanes, network components as well as cable harnesses for networks or machinery, or for power and data application in factories, RFID systems.
HARTING CANAdA, INC. 8455 Trans-Canada Highway, Suite 202 St. Laurent, QC, H4S 1Z1 Phone: (855) 659-6653 Email: info.ca@HARTING.com
www.HARTING.ca
Relax, tomorrow has already been tested. Simplify with HARTING connectors
Reduce the number of needed components and save space. HARTING, first established in 1945, delivers unrivaled reliability, efficiency, performance and innovation. With HARTING you have a partner who ensures you dependable connections that stand the test of time.
www.HARTING.ca
Technology handbook
Power Supplies
IMO’s dPS power supplies provide a dependable and reliable choice for electrical and electronic devices in control & automation applications.
I
MO’s DPS range of 24VDC, Din Rail mounted power supplies have been specially designed and built for long lasting provision, and protection of 24VDC devices ranging from instrumentation and robotics to general control, Programmable Logic Controllers, and Human Machine Interfaces. With the security of IMO’s 3-year warranty, the DPS range delivers reliability and dependability to a variety of applications. The IMO DPS power supplies deliver an 89% efficiency, and are available in a variety of wattages from 5 to 480W complete with shortcircuit protection, and an integrated internal input filter. IMO DPS power supplies come in five sizes; 5W, 10W and 18W, class 2, slim-line power supplies are only 22.5mm wide. The 30W and 60W units are 40.5mm and like the smaller wattages, are contained in robust plastic enclosures. The larger size power supplies are manufactured in metal enclosures which include 120W units (63.5mm), 240W units (83mm), and 480W, 20A (175mm) wide. The DPS supplies offer the advantage of a universal input voltage range, of 85V – 265VAC and, as standard, are supplied with a 24VDC output; 5V, 12V and 48V versions are also available. IMO DPS power supplies have been successful in client’s applications using IMO’s latest innovation, the i3 controller. This unique one-piece controller, that combines a PLC and HMI into one controller, requires a dedicated and reliable power supply. As the PLC’s inputs and outputs are mounted to the controller, the DPS power supply is also used to power analogue devices, and external IMO limit switches, photoelectric and inductive proximity sensors, as well as a number of push buttons and 24VDC pilot lights. In solar applications, the 120W DPS power supply has been used with IMO’s SolarCube solar tracking controller,
4 MA • Technology Handbook Power Supplies
delivering reliable power to the controller as well as the compass and GPS antenna. This also provides 24VDC power for the relays and IMO’s Jaguar Variable Frequency Drive controlling the movement of a solar array. In robotic applications, having a parallel output function for two 120, 240, or 480W DPS power supplies mounted and wired together provides power back up should one of the units become disabled. When these DPS power supplies are wired in parallel, the two supplies drop to half the wattage, given a total wattage equivalent to the amount they are rated for. Should one of the supplies fault, the other puts the wattage to full, supplying reliable power to crucial systems. Reliable power is a must for food and beverage processes. The 60W DPS power supplies work exceptionally well with IMO’s TD series of temperature and process controllers. We challenge you to compare your power supplies to IMO’s DPS power supply for price and warranty. If you have any questions on any of the products mentioned, please contact Manufacturers Automation Inc.1-800-387-6268 or manuauto.com for more details.
Manufacturers Automation Inc. 1600 King Street North, St. Jacobs, ON NOB 2N0 Toll free: 1-800-387-6268 email: sales@manuauto.com
www.manuauto.com
Technology handbook
Power Supplies
The Power Supply Unit with Maximum Efficiency
M
urrelektronik presents Emparro, a highly innovative power supply unit with maximum efficiency and minimum power loss. The combination of the Power Boost function with a power limiter output allows large loads to be started easily. The wide input voltage range makes Emparro a global player. Modern machine builders and users are paying attention to power consumption. Our new power supply units put the focus on efficiency because energy is a precious commodity and unused machine energy increases costs. Emparro sets new standards – thanks to an innovative circuit concept. Emparro’s efficiency rating is up to 95 % – an impressive result that means only 5 % of the energy remains unused. Compared to power supplies with an efficiency rating of about 90 % and a power loss of 10 %, Emparro reduces power loss by 50 %. This is an impressive improvement that has positive effects on your wallet – especially over the life of the machine. Because of Emparro’s low power loss, the power supply generates less heat. This means less thermal stress for the individual components and increases Emparro’s lifetime. The same applies for the components installed near Emparro. Those units benefit from lower heat exposure than conventional, less efficient, power supplies. Thus, they last longer and reduce purchasing and maintenance costs. And you can even think about choosing smaller control cabinets now. It’s not only its efficiency that makes Emparro an advanced power supply unit:
Emparro supports startup: Emparro offers Power Boost, providing up to 150% more power for up to 4 seconds. With this Power Boost function you can start higher loads and capacities without requiring a second power supply unit.
6 MA • Technology Handbook Power Supplies
Emparro optimizes the overload behavior: In the event of short-circuits or overload, Emparro’s output voltage is controlled with a constant current. It is limited to 100% of the nominal current (or to 150% in Power boost mode). This power limiter function protects the power supply unit reliably from damages caused by overloads and is an important aid when starting up. Emparro is a global player: Murrelektronik‘s new power supply units feature a wide input voltage range from 85 to 265 V AC (90 to 250 V DC). This makes Emparro suitable for worldwide use. Emparro is available in seven different models, with output voltages of 12, 24 and 48 V so Emparro can be a solution for many different applications. The metal housing ensures optimum EMC characteristics. The units work reliably because of a wide optimal temperature range from -25 to +60° and continuous high-performance without derating. A signal contact enables remote diagnostics: It signalizes shortcircuits, overloads and excessive temperatures.
Murrelektronik Canada 6325 Dixie Road, Unit 5 Mississauga, ON L5T 2E5 Phone: +1 905-362-2211 Fax: +1 905-362-2101 E-mail: info@murr.ca
Murrelektronik Quebec 3755-E Boul. Matte, Suite 110 Brossard, QC J4Y 2P4 Phone: +1 514-461-7282 Fax: +1 514-221-3447 E-mail: info@murr.ca
www.murr.ca
www.murr.ca/ca-fr/
Technology handbook
Power Supplies
Meeting High demands of Oil & Gas Industry
P
anel designers have a lot to consider when choosing which type of switching power supplies for their control panel, but for panels going into oil and gas extraction operations, the stakes are that much higher due to the risk of explosion. They must take extra caution and ensure that those power supplies meet the demands of a hazardous environment with extreme temperatures. The unique features of Omron’s new power supplies have made that decision an easier one for panel designers for these three reasons:
• Withstands extreme cold and hot temperatures, from -40° to +70°C, in enclosed outdoor use • Resists shock and vibrations up to 5G without de-rating performance • Meets CSA Class 1 Division 2 ratings for use in hazardous environments “The -40°C temperature feature of the new S8VK-G series enables us to provide power supplies to applications in far north drilling, as well as Arctic drilling applications,” said Wade Johnston, Account Manager for Omron Automation and Safety in Canada. “The Class 1 Division 2 rating is a crucial feature for any of our customers with oil related applications.” Another important factor for panel builders to consider is product size, particularly the mounting depth. The panel’s ultimate depth and size is where designers can control costs and improve project profitability. The S8VK-G power supply — and many other Omron panel mount controls — have shallow mounting depths and slim footprints that save space and allow use of smaller control cabinets. “The reduced cost of using a shallow depth cabinet can typically save $100 in material costs for the project,” according to Johnston. The Advantages of Thermal Technology By using thermal technology, Omron was able to identify the hot spots inside the power supply that tend to decrease the life of a power supply. Omron positioned the components that get the hottest close to the top vents, maximizing dissipation of the heat through gravity ventilation. This design eliminates the need for fan forced ventilation in higher wattage models and allows an overall decrease in
8 MA • Technology Handbook Power Supplies
the physical height of the power supply. “One of our customers came to us with the need to build a panel for an oil patch pumping station, and they needed to conserve space, while maintaining high efficiency,” Johnston said. “Omron’s new power supply design gave them that capability at a better price point and shorter lead time than our competitors could offer.” Simplified Wiring The S8VK power supplies provide two sets output terminals to simplify wiring of two loads. The layout reduces installation and servicing time as well as the cost of twin entry ferrules required when only one set of output terminals is available. Full Line of Compact Power Supplies Omron offers four different S8VK-series compact power supplies to match every customer’s needs. • S8VK-C – Most cost-effective • S8VK-G – Standard single-phase input • S8VK-T – Standard three-phase input • S8VK-R – Redundancy Unit Our high quality power supplies are backed by 80 years of experience and global support. • Learn more about Omron power supplies: http://industrial.omron.ca/en/products/catalogue/control_components/power_ supplies/default.html • Additional Omron information can be found at omron247.com. • Omron on Social Media: http://industrial.omron.ca/en/news/social_media/omron_on_social_media.html • Contact us: http://industrial.omron.ca/en/contact/omron_in_country/default.html
Omron 885 Milner Avenue Toronto, ON M1B 5V8 Toll free: +1 (866) 986-6766 email: askomron@omron.com
www.omron247.com
When you take your automation to extremes...
We’ve got the power to help! Failure resistant in tough environments Whether installing in extreme temperatures or hazardous locations, Omron’s Switching Power Supplies S8VK-G Series guarantee stable operation.
Easy installation The double set of terminals allows for quick, easy wiring of dual loads, while keeping them isolated from each other.
Compact size The S8VK-G offers a wide product range (from 15W up to 480W), in a very compact size. It is 13 percent smaller than comparable power supplies and the smallest of its type on the market.
It’s improved DIN-rail mounting clip provides better vibration resistance.
Find out how Omron Power Supplies can meet your demands at omron247.com OMRON AUTOMATION AND SAFETY • Canada toll free: 866.986.6766 • www.omron247.com
Technology handbook
Power Supplies
Short circuit Enhanced protection and remote reset capabilities increase the efficiency of SCADA/RTU systems By dAvId WHITAkER
P
rocess automation projects are most often driven by bottom line results, return on investment and an appropriate value position or justification. More and more, systems are expected to:
• Provide access to quantitative measurement points of important processes; • Detect and correct problems immediately; • Measure trends; • Pinpoint and eliminate bottlenecks; • Control larger and more complex processes within a large geographic area; and • Maintain constant communications and an uninterrupted power source. All of this can be accomplished using a SCADA system within the automation process. None of these functions, however, are available if the system is not designed with a reliable power source for the remote panel portion of the SCADA system. Using the latest circuit protection technology available can increase the efficiency of a battery-powered remote panel deployed with a SCADA system. Before we can go into the details of the newest circuit breaker technology for SCADA systems, however, we need to review what a SCADA system is and its function within the automation process. A brief introduction to SCADA Supervisory Control and Data Acquisition, better known as SCADA, is used in systems where real-time data is gathered from multiple areas or locations of the automation process located anywhere from a few hundred feet to miles away from a central control panel. SCADA systems provide sensing and monitoring capabilities, as well as the computational power to track everything relevant
10 MA • Technology Handbook Power Supplies
to the process and manufacturing operations. This is accomplished with the use of four basic component groups: 1. Sensors and instruments: Devices measuring the variables of the process connected to a dedicated controller. 2. Remote Telemetry Unit (RTU): Small computerized units deployed in the field at specific sites and locations. RTUs serve as local collection points for gathering data from sensors and delivering data and commands to the master unit. (See Figure 1) 3. SCADA Master Units: Typically, this is an industrial-grade PC that displays detailed graphics of all the field devices, and has the ability to process multiple communication interfaces and protocols. The graphics represent the actual field devices in the form of gauges or some type of device status, such as pumps, flow meters, tank levels, temperature gauges, switch position, etc. 4. Communication networks: These networks connect the SCADA Master Units to the RTUs in the field. There are many communication interfaces and protocols available, from very simple to very sophisticated, with extremely high speeds and large volumes of data. Early SCADA systems used basic serial communication, running at a very slow speed of 1,200 baud (number of times the signal changes in a second) over a radio-based transmitter/receiver. This approach worked fairly well for the amount of data required over radios with relatively short distances. Today, typical systems are operating at 100 Mbps (one million bytes per second) over similar radio technology or wireless Ethernet technology, allowing communication now to reach distances of 10 to 20 miles consistently. The shortcoming of SCADA systems and traditional circuit protection SCADA systems are using more and more batterybased power sources connected to solar power recharging units
Technology handbook
Power Supplies
Figure 1
Figure 2
rtus serve as local collection points for gathering data from sensors, and delivering data and commands to the master unit.
in the event of a fault, the electronic circuit breaker immediately detects the faulty load in the circuit.
for remote field enclosures to avoid running expensive AC power lines. Industrial batteries have evolved over the years to provide longer-term power than in the past; in most cases — up to 36 hours or more. Along with battery improvements, the RTU, radio communication and instrument manufactures have reduced the amount of current required to operate these devices to monitor and collect data. These factors have driven SCADA architectures to incorporate battery systems as the primary power source. While there is a great deal of value available with this design approach, there is one area of concern that needs to be addressed: the short circuit and overload protection. Traditionally, automation applications have used fuses or low-cost circuit breakers to provide the overload and short circuit protection for components installed in enclosures and in the field. Fuses will quickly detect a fault in any of the components installed and provide disconnection from the power source. Standard circuit breaker technology provides a few options to select from, including thermal, thermal-magnetic and magnetic. Similar to a fuse, each of these devices fit a specific type of protection for short circuit and/or overcurrent protection, and provide disconnection from the power source. However, both of these technology approaches have a significant deficiency, which SCADA systems have a difficult time dealing with. Once the device trips as a result of a fault, it immediately goes offline and the protection device must be manually reset or replaced to bring the device back online. This requires a field engineer to travel to the panel location and reset the breaker or replace the fuse. The downtime of a SCADA system due to a fault is highly inefficient and very costly. Additionally, when data is not available to the SCADA master unit, it is blind to what is happening in the field and, in some cases, this information is tied to revenue generation for the end customer. Most of these systems have redundant devices in place to have multiple measuring points feeding the SCADA system, which helps deal with a single device
going offline. Not all industries can afford redundancy of devices, and there could be a fair distance between devices, which might cause alarms or errors in how the overall SCADA system reacts to a single point of failure. Remote reset circuit protection helps solve the shortcomings of SCADA systems. Now let’s take a look at a new circuit breaker technology based on solid-state electronic MOSFET technology with integrated remote reset input. For the first time, circuit protection can be integrated into an RTU as seamlessly as the field devices, providing the convenience of resetting or cycling the power to any of the components connected in the remote panel. In the event of a fault, the electronic circuit breaker immediately detects and disconnects the faulty load in the circuit, and enables a system engineer to reset the circuit breaker remotely with a simple relay, pushbutton or RTU output via a command from the SCADA master unit over a wireless radio communication network, as seen in Figure 2. Compared to traditional circuit protection solutions, using a remotely resettable electronic circuit breaker will prolong the energy life of the batteries and deliver more productivity of the entire SCADA system. To deploy a remote panel in any architecture, whether the distance is 500 feet or miles away, the panel needs to be self-sufficient or have the ability to be controlled from a centrally located controller. Serviceability, or the lack thereof, is an extremely important attribute of the remote panel in a SCADA system. If a remote panel needs to be visited or maintained on a regular interval to deal with any of its components or its overall functionality, then its inefficiency will increase the cost of the entire SCADA system overtime. As battery-powered solutions become more acceptable in the SCADA application environment, so will the need for the appropriate circuit protection with remote reset functionality. David Whitaker is an applications/product specialist with E-T-A Circuit Breakers. Reach him at www.e-t-a.ca. Power Supplies Technology Handbook • MA 11
Technology handbook
Power Supplies
EmpowErEd
auTomaTion PuTS you in conTrol of your energy coSTS By PAtty SOLBerg
P
eak power is expensive power — sometimes very expensive. In Ontario, for example, businesses with an average peak demand over five megawatts could pay a “global adjustment” charge of $350,000 per megawatt of load they contribute to this year’s top five peaks, according to the consulting firm NRG Matters Corp. And that’s in addition to regular usage charges.
But industrial facilities are not simply at the mercy of peak power charges, and manual shutdowns are not the only option for reducing peak usage. Businesses that use an automated demand management system can cut energy costs without compromising production or quality — even when they have complex, demanding production processes. The key is to take full advantage of a suite of demand management strategies: demand control, demand response and dynamic pricing optimization. Using technology with sophisticated analytic capabilities allows businesses to optimize each of these strategies by drilling down into the performance of specific loads, comparing current and historical data, and viewing data across the enterprise. Managing demand peaks safely and effectively A demand management system automatically curtails only the loads needed to meet your savings goals, rather than making large, predefined reductions (as peak demand limiters do). The ideal demand management system will integrate with your existing control systems and extend their functionality. A system that includes the following features will let you manage demand optimally without endangering critical processes or reducing overall production output: • Pricing intelligence: An algorithm calculates peak demand based on your utility rate schedule, avoiding needless reductions that bottleneck your processes. • Rule-based actions: The system lets you specify which loads it can reduce at which times — and doesn’t break them. It can prioritize loads sequentially, by group, or by process logic to optimize your energy use, and it can synchronize load shedding to achieve both savings and productivity targets. • Facility-wide control: Incorporating as much of your facility as possible into control actions broadens the opportunities for load shedding, letting you optimize energy use and minimize disruptions. Such a system will not only reduce your facility’s electricity costs, it will also deliver business insights. Demand management automation gives you access to real-time data from plant equipment, and with full visibility into your facility’s energy use, you can monitor equipment efficiency, calculate product costs more accurately, anticipate equipment failures, and act on data in real time.
12 MA • Technology Handbook Power Supplies
Power Supplies
Essential demand management strategies Demand control: Demand control (DC) involves preventing demand spikes, rooting out inefficiencies and shifting power demand to the lowest-rate periods. An advanced demand management system allows you to do this safely and reliably by automating strategic demand reductions over a collection of loads so that you can maintain productivity. It can prioritize loads sequentially, by group or by other conditions such as process status, type of material, time limits or when a load was last curtailed. It can also orchestrate load shedding to achieve both savings and productivity targets. Actions the system might take include: • Turning equipment off when there’s a process buffer; • Adjusting temperature setpoints; • Slowing or shutting down fans; • Reducing power to finishing equipment, such as grinders or motors, when it’s not needed; • Reducing wastewater treatment loads to minimize energy consumption by blowers, agitators and pumps; • Shutting down battery chargers; and • Delaying the start of vacuum tubes or grinders. The savings can be significant. Peak-time energy use can account for as much as 40 per cent of an industrial user’s electricity bill, so avoiding these spikes can reduce the overall bill by as much as 15 per cent. For example, one northeast foundry saved more than US$64,000 annually using demand control. Another foundry in Mexico achieved a 26 per cent decrease in kilowatt-hour usage and a 55 per cent reduction in peak demand, resulting in US$45,000 of monthly savings. And a Toronto-based food distribution operation is saving US$38,000 a year through demand management and energy efficiency measures. Demand response: Utilities and power system operators — including those in Alberta, Ontario and Quebec — use demand response (DR) programs to relieve stress on the grid and reduce the need to build new power plants. DR programs pay electricity users to reduce consumption on demand, typically when the grid is experiencing spikes in power demand. For example, when a heat wave or cold snap causes a demand spike, a utility might call on DR participants to reduce their usage by an amount specified in their contract. There are numerous types of DR programs with varying names and requirements. With more traditional programs, which provide advance notice of events that typically last two to four hours, businesses may participate manually by simply turning off equipment for the DR period. However, manufacturers who use a demand management system can draw on the inherent capacity in their processes to make fine-tuned reductions in power use and avoid complete shutdowns.
Technology handbook
“In Ontario, businesses with an average peak demand over five megawatts could pay a global adjustment charge of $350,000 per megawatt of load they contribute to this year’s top five peaks” Consulting firm NRG Matters Corp.
Canadian plants subject to global adjustment charges can use a demand management system in a similar way. Class A customers (those with an average peak demand more than five megawatts) pay the system operator a global adjustment charge — essentially their share of peak power demand — to cover power costs not covered by fixed business and residential rates. This charge has risen steadily in the past several years, and companies subject to it typically sign up for a peak advisory notification service to warn them of forecasted high peaks so that they can avoid “coincident peaks” (the ones that incur charges). A demand management system allows manufacturers to react to those warnings with strategic, automated load-shedding actions that minimize global adjustment charges as well as production impact. The latest DR programs require automation, and they tend to be the most lucrative. In these programs, the business’s and the utility or grid operator’s systems “talk” with each other using a standard such as Open Automated Demand Response (OpenADR), with a Smart Demand Response Automation Server (Smart DRAS) client providing a dynamic connection. The utility’s system notifies the user’s system of a DR event, and the user’s system takes action according to the energy usage rules set for that facility. Dynamic pricing optimization: Dynamic pricing strategies, such as paying spot market costs for electricity, involve rate changes based on the market price of electricity, weather events or other conditions. An advanced demand management system lets businesses respond automatically to ongoing price fluctuations by shifting consumption to lower rate periods or reducing consumption during costly super-peak times. Implementing such strategies, in addition to the automation to manage it all, can result in significant savings for manufacturers. Power doesn’t have to be expensive. Patty Solberg (pattys@poweritsolutions.com) is the director of product marketing at Powerit Solutions (www.poweritsolutions.com), a Seattle-based international technology company that focuses on advanced energy demand management. Power Supplies Technology Handbook • MA 13
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