CD Automation has released a single loop temperature control & power solution that dramatically reduces wiring costs and cabinet size. The REVO TC combines a temperature controller, solid state relay (thyristor), quick blow fuse protection and current monitoring, all in a compact single loop package.

It is estimated that an immediate saving of 2 hours per loop can be achieved by the reduction in wiring time alone; resulting [...]]]> CD Automation has released a single loop temperature control & power solution that dramatically reduces wiring costs and cabinet size. The REVO TC combines a temperature controller, solid state relay (thyristor), quick blow fuse protection and current monitoring, all in a compact single loop package.

It is estimated that an immediate saving of 2 hours per loop can be achieved by the reduction in wiring time alone; resulting in significant cost reduction when multiple loops are required. Add to this the material
cost, reduced cabinet size due to the smaller footprint, and it’s clear to see how real cost savings can be made.

Available in 1, 2 & 3 phase units and numerous amps sizes up to 210A, the power unit comes with fuse protection and built in current transformer, allowing heater element diagnostics via the units front panel display. The special heat sink design provides optimum heat dissipation and allows space saving, side by side mounting. The universal input offers a choice of thermocouple, 3 wire PT100 and linear input signals to the PID temperature controller with up to 4 configurable outputs. These can be used for heat & cool control, alarms and recorder output. Traditional screw terminals or optional RJ45 connectors aid quick & easy installation.

1 phase

2 phase

3 phase

The all-powerful CMC-99 comes with up to 48 analogue/digital inputs and up to 60 virtual channels, all in a 96 x 96mm package. Add to this an in-built recorder with 1.5GB of data storage plus a colour touchscreen, and you have remarkable 1/4 DIN control/recorder package solution.

A fully configurable 3.5” touchscreen allows the operator to choose which parameters to display on the CMC-99 controller/data-logger, and in which graphical [...]]]> The all-powerful CMC-99 comes with up to 48 analogue/digital inputs and up to 60 virtual channels, all in a 96 x 96mm package. Add to this an in-built recorder with 1.5GB of data storage plus a colour touchscreen, and you have remarkable 1/4 DIN control/recorder package solution.

A fully configurable 3.5” touchscreen allows the operator to choose which parameters to display on the CMC-99 controller/data-logger, and in which graphical format such as chart, bar-graph, dials or numeric values. To help with device configuration it is possible to connect a standard USB keyboard and mouse directly
to the CMC-99.

Example unit: 16 x Voltage inputs, 16 x SSR drive outputs = £650, thats only £41 per loop

Multi-loop Controller & Data-logger

The CMC-99 logging controller can provide up to 8 proportional, integral and derivative (PID) control functions along with up to 8 separate ON/Off alarm relays depending on power rating. The internal data-logging memory of the CMC-99 process controller can store up to 250 million samples of data. The data-logging desktop software package is used to retrieve data and groups it to produce graphs or tables. If you like your touchscreen slightly larger, it’s bigger brother, the CMC-141 has a 5.7” display, more inputs/outputs and even more logic channels.

Improved process control result in lower costs by monitoring

the process online and adjusting the configuration via the clear
and interactive configurator screen.

This easy to load and fully Windows compatible software allows the user to configure inputs/outputs and associated features, upload and/or create commonly used recipes and download to one or more thyristor power controllers within seconds of connecting the transfer cable.

From the convenience of your PC or [...]]]> Improved process control result in lower costs by monitoring

the process online and adjusting the configuration via the clear
and interactive configurator screen.

This easy to load and fully Windows compatible software allows the user to configure inputs/outputs and associated features, upload and/or create commonly used recipes and download to one or more thyristor power controllers within seconds of connecting the transfer cable.

From the convenience of your PC or Laptop the REVO Thyristor unit can be finely tuned for improved control, and diagnostic monitoring of variables such as internal power, current and voltage, therefore saving valuable commissioning time.

The benefits to the user are a significant reduction in the units’ setup time, real-time process variables such as power, current and voltage are graphically displayed providing the ability to adjust the input power, firing rate, current limit and power scaling online.

Reduce the need for stocking multiple products with different input types, firing modes, heater break and current limit settings; standardise a smaller range of units and configure them at the time of need.

The software comes on CD with a dedicated USB cable and is suitable for use with the complete comms enabled REVO Thyristor Power Controller range.

For more on Thyristor visit www.cdautomation.co.uk

Collins Walker Limited is a world force in the manufacture of electric steam and hot water boilers. It is one of the few companies in its field which design and manufacture the whole boiler system in-house, including the pressure vessels, cabinets and controls. Supplying both immersion and electrode systems, Collins Walker customize each boiler to exactly meet the client’s needs, and the company [...]]]>

Collins Walker Limited is a world force in the manufacture of electric steam and hot water boilers. It is one of the few companies in its field which design and manufacture the whole boiler system in-house, including the pressure vessels, cabinets and controls. Supplying both immersion and electrode systems, Collins Walker customize each boiler to exactly meet the client’s needs, and the company exports over 50% of its production.

The electrode boilers are more robust than immersion types, in part because they don’t use heating elements and the switching needed to control them. They are more tolerant of current and voltage fluctuations, and so are popular in places like Africa and the Middle East where power supplies are not as reliable as those in the UK.

Immersion boilers and relay contactors

Since the company was set up in 1972, its immersion boilers have used relay contactors to control the switching of power to the elements. On larger boilers, this can amount
to a bank of up to 60 contactors. With their associated wiring, contactors can be a source of faults, and require regular maintenance.

Although having multiple contactors gives some degree of control by staging the switching,
the boiler and the electrical supply can still be subject to power surges. With larger boilers rated at thousands of kilowatts, even Collins Walker’s power station customers are concerned about the huge draw when boilers are switched on.
The heating elements themselves suffer thermal shock each time the power is switched,
and this leads to element failures.

Looking for an alternative

As part of its product development, Collins Walker has been working on ways to improve the reliability of components, reduce the need for maintenance,
and improve the energy efficiency of their boilers.

Due to the continual switching, contactors wear out and need replacedment. As the larger boilers can have up to 60 stages, each with their own contactor, maintenance can become a significant time and cost factor. As contactors on have two states, on and off, the elements they control are subject to a thermal shock as the power goes from off to full on, and back again.

Finding a solution to the problems caused by the switching had become an increasingly urgent task. By replacing the relay contactors with a thyristor controller, Collins Walker has found it can address all these problems, and improve energy efficiency by giving much finer control of the power being applied to the boilers.

Thyristor control

Although thyristors are more expensive, one can replace many contactors. Particularly in large boilers with many stages, there is a saving in manufacturing time and cost as the wiring is significantly reduced.

The most important advantage of thyristor control is their ability to gradually apply power to the elements in the boiler, virtually eliminating the problem of thermal shock, and extending the life of the heating elements.

Without the physical contacts found in contactors, a thyristor controller doesn’t wear out with the continual switching.

Choosing CD Automation

There are a number of potential suppliers of thyristor controllers, and Collins Walker needed to choose the right one to gain the maximum benefit from the change in switching specification for its boilers.

With the two main contenders offering units with broadly similar benefits for the boilers, Collins Walker, needed to understand the factors which might affect the production side of the equation.

One company produces very sophisticated thyristor controllers. However, from Collins Walker’s perspective, there is far too much functionality built in to these. Much of this was of no practical use to the company, and meant the units are very complicated to set up. In fact, this process is so complex, an engineer from the supplier is needed to set up each thyristor during production of the boiler. This complicates production scheduling for Collins Walker, and can result in delays if the engineer needs to come out again.

CD Automation’s thyristor controller has been designed for ease of installation, and Collins Walker is able to configure and set them up in house. Chris Goddard of Collins Walker says of the CD Automation units,

“They are simple to set up, controllable, and cost effective.”

This was the key consideration in the final choice of CD Automation’s thyristor controllers.

Working with CD Automation

Collins Walker has been impressed with the availability, knowledge and enthusiasm of the staff at CD Automation. Chris Goddard comments,

“They’re very good, actually. When ever you ring them, they’re always there to answer the phone.”

During the installation of the first CD Automation thyristor controller, Collins Walker staff asked them lots of questions, and were sometimes on the phone with them for over an hour. CD Automation did not spare any effort in ensuring Collins Walker were able to successfully install the first thyristor controller themselves. Chris Goddard summed them up:

“So, I’m quite impressed with them.”

Thyristor control

Collins Walker now use CD Automation’s thyristor controllers on all but the smallest boilers – those less than 100 kW which only have one of two contactors.

The controllers are programmed to bring in the power gradually, for example starting at 10% for a few seconds before moving on to 20%, and so on. The power is also reduced gradually, smoothing the whole process of switching the power on and off.

The thyristor is attached to a PLC (Programmable Logic Controller), forming part of a PID Loop (Proportional Integral Derivative). This is a specialised feedback system which helps to anticipate the lag in the system, so the switch on or off occurs just before it’s needed. This prevents thermal overshoot, where the elements are still supplying heat after the set temperature has been reached and the power switched off, making the boiler more energy efficient. This is only possible with thyristor control as a PID Loop cannot be implemented on a boiler using contactors.

The outcome for Collins Walker

Using the CD Automations thyristors, Collins Walker is able to maintain complete control of its boiler production, and is producing a product which requires less maintenance and is more energy efficient.

The maintenance and energy savings are passed on to Collins Walker’s customers, improving their ability to win contracts for the supply of robust, reliable and efficient boilers.

The REVO-CL from CD Automation is designed to aid customers in selecting the right thyristor power controller for their application.

With high in-rush current on start-up, close examination of the application needs to be made to ensure fuse or thyristor failure does not occur.

Typically, two firing techniques can be considered: phase angle firing with soft start and current limit or burst firing with delayed triggering.

The [...]]]>

The REVO-CL from CD Automation is designed to aid customers in selecting the right thyristor power controller for their application.

With high in-rush current on start-up, close examination of the application needs to be made to ensure fuse or thyristor failure does not occur.

Typically, two firing techniques can be considered: phase angle firing with soft start and current limit or burst firing with delayed triggering.

The REVO-CL allows users to select either type, via the units front keypad or via RS485 communications.

Both are standard features, removing any risk of specifying the wrong firing technique at time of order.

Further flexibility gives the user a choice of inputs from DC Linear 0-10V or 4-20mA, DC Logic 4-30V, 10K potentiometer or RS485, firing modes and control feedback of V2, V, VxI and I.

All can be accessed and selected using the standard RS485 port, front keypad and display or via the front fascia configuration port and dedicated PC software.

Typical load types for the single phase REVO-CL include normal resistance, infrared long, short and medium waveform, silicon carbide and cold resistance.

The small footprint reduces the base plate mounting area by up to 50 per cent and in-built safety with internal high-speed fuses is also included.

With its quick conversion of fast transient processes, reading & controlling pressure  sensors is made easy with the PIXSYS ATR243 Process Controller.

The outstanding analogue-to-digital converter of the ATR243 (as with all ATR models) makes this controller particularly suitable to read and control processes with quick transient/step changes, such as with pressure measurements.

Key features of ATR243 include:

• Programmable sampling time up to 252 Hz
• Configurable software filter ensures [...]]]>  

  With its quick conversion of fast transient processes, reading & controlling pressure  sensors is made easy with the PIXSYS ATR243 Process Controller.

  The outstanding analogue-to-digital converter of the ATR243 (as with all ATR models) makes this controller particularly suitable to read and control processes with quick transient/step changes, such as with pressure measurements.

  Key features of ATR243 include:

  • Programmable sampling time up to 252 Hz
  • Configurable software filter ensures stability of value visualized on display
  • Power supply source for the transmitter
  • Relay outputs programmable as command or alarm

  We distribute transmitters as well but of course compatible devices of other brands may
  also be used.

  Download our Free Application note AP_PIX_0042_0211 with wiring and software parameter examples.

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