Energy: Use and…. Re-Use???

January 12th, 2010

With all the talk these days about “Green” this and “Green” that, eventually you have to start wondering about your own “carbon footprint”. In our industry, Everything… Is… Of…or About… Energy. So I had the thought: each of us is in one way or the other, concerned about the cost of energy. There is the “cost” in terms of what energy use does to the environment; or the cost in terms of how it affects your bottom-line.

As humans, we all tend to be short-sighted. Most of the time, things have to be pointed out to us (hopefully by someone smarter than we are) for us to take note. Getting to the point, I was recently introduced to a product (by some really smart people) which really made sense to me. I’d like to share it with you, because it addresses at the same time – both the bottom line cost and the long term impact of energy use.

Bear with me here. Most 5th Graders know that when a motor starts, it uses electricity. Electricity costs money. So if you can create something which only uses as much energy as necessary and no more, then you really have something! That (ask any 5th Grader) is why Inverters (or Variable Frequency Drives) are so cool! If you have something in your little plant or giant factory which might use 10HP, you have to have a 10HP motor. But if most of the time you only use 5 HP, and can “turn down” the motor where it is only developing 5 HP – then it only uses the energy of a 5HP motor. Need only 1.5 HP? Turn it down and reap the savings. Neat, huh!

So for the past  decade or two, Inverters (I like to call them VFDs or just Drives), have been the “cat’s meow”. So much so, that the electrical company even gave people money back on their bills, because they didn’t have to build new power plants. Now, let’s move on to 6th Grade stuff.

We all know (see above) that motors use electricity, but how many of us knew that (4th Graders pay attention here) motors can MAKE electricity? Yep! They really can. And they really do, when the guy in the control booth (actually he is a computer, but don’t tell anybody) tells the Inverter to slow the motor down, electricity is actually made by the motor! Now the Inverter has to DO something with that electricity. So it turns it into heat! That is a bad thing. What’s worse, is that if the guy in the white shirt and tie up in the front office says to slow the motor down even faster, then the Inverter gets connected to a big toaster (we call them “Dynamic Braking Resistors”, but they really are just big toasters. Without the toast.) Big Toaster = Big Heat = Wasted $ = Bigger Carbon Footprint. That’s a bad thing.

So these smart guys I know (not really, but it makes me sound way cooler than I am) came up with a really clever idea. What if you could throw away that big toaster, and take that electricity that would have been turned to heat, and (now get this) SELL IT BACK to the electric company??? Whoa! Now you have something to write home about! Well to be honest, “sell it back” might be a bit of a stretch – “have it available for use elsewhere” in your facility might be more accurate. But the end result is the same.

This “gizmo” is called a RCU – “Regenerative Converter Unit”. Here are the details: Vertical lifting machinery or high inertia loads like elevators, cranes, centrifugal fans and centrifuges contain potential energy and inertial energy when operating. When the motor is operated by an inverter, this energy is converted back into electrical energy when the devices decelerate, lower or stop the load. This electrical energy, called regeneration, flows back into the inverter’s DC bus, causing the voltage to rise.

• Traditionally, this regenerative energy is dissipated as heat through dynamic braking resistors, and is therefore wasted.
• The RCU series Regenerative Converter can provide up to 40% energy savings, by reclaiming that regenerative energy and feeding it back into the AC supply.

At this point your head jerks towards me (and the 6th Grader named Paul), and you say “How can this be”?   

Well, the RCU Regenerative Converter reduces electric power consumption by returning the otherwise wasted energy to the AC power distribution network for use by other loads.  Additionally, because there is no heat generated by braking resistors, the capacity of air conditioning systems in the electrical room can be reduced, further reducing electric power consumption.

I started out this blog talking about energy. The RCU is also ideal for use in “Renewable Energy Systems”, like Solar/Photovoltaic systems, Wind Turbines, and Fuel Cells. So I’ll end as I began, by using the (by now almost overused) term, “Green”. If you are reading this blog on a webpage called Lighthouse PLCs, Inc., you are most likely involved in some fashion with the manufacturing industry. You are the guys and gals who make the stuff we use every day. (Thanks, by the way.) But it isn’t everyday that we at Lighthouse get to offer you something that at the same time helps your bottom line and also helps the environment. That, my friends, is pretty neat! And you don’t have to be 6th Grader to appreciate that.

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RIFs, layoffs, cutbacks: Do’s and don’ts

November 26th, 2009

I came across a VERY interesting article in this issue of ISA’s InTech (15 October 2009) Magazine, by Jim Pinto.  Rather than take your time with my inane diatribe, I have reprinted (with the author’s permission (on file)) the article in its entirity.  I am excited to present Jim’s article here.  If you find it as pertinent as I did, leave a comment.

RIFs, layoffs, cutbacks: Do’s and don’ts

By Jim Pinto

Just recently, I saw the HBO documentary: “The Last Truck – Closing of a GM plant.” GM employees who had been with the company for 20 to 30 years sadly followed the last truck as it rolled down the assembly line. Reactions ranged from philosophical to sentimental; many could not speak as they became overwhelmed by tears.

The late-1950s bestseller, William H. Whyte’s Organization Man described General Motors. People not only worked for the organization but sold their psyches as well. They willingly subordinated their personal goals and desires to conform to the demands of the corporation. Half-century later, here was the demise of GM, the model company Whyte’s book was describing.

During these recessionary times, big layoffs seem to be the only solution to our economic woes. Already many states have unemployment rates of more than 10%, and the national average is creeping up to that level.

There are several expressions used to make the nasty job of layoffs more palatable—cutbacks, downsizing, reduction-in-force (RIF). Consider this: When your colleague is RIF’d, it is a recession; when YOU are RIF’d it is a depression.

Most employees who are let-go are given “the standard company severance package.” In the U.S., it is usually a week per year of service. In Europe, it is much more difficult (and expensive) to layoff anyone who has been employed for a few years.

There are strict laws involved, usually covered by making exiting employees sign a document waiving any further claims before they receive their final check. Under these difficult circumstances, few have the knowledge or the fortitude to really read the document; many simply sign away their rights in order to accept immediate payment. Most companies tread the fine line between decency and legality in the layoff process. It is tough for everyone—the company, the exiting employees, and the ones remaining.

Here is my own list of Do’s and Don’ts for laid off employees:

  • Don’t take it personally.
  • Don’t blame anyone.
  • Don’t simply look for another similar job, at a similar pay.
  • Do your best to stay positive.
  • Do use this opportunity to re-educate and modernize yourself.
  • Do find something you enjoy; hey, maybe start your own business.

Here is my advice. Being laid off could be the step that pushed you into something you will enjoy much more. Develop a NEW YOU – Version 2.0. You might end up with an occupation that is much better than anything you thought possible.

My mother told me long ago: “People like to do what they’re good at, and are good at what they like to do.” Find something you are good at, and you will like doing it.

Behind the byline

Jim Pinto is an industry analyst and founder of Action Instruments. You can e-mail him at jim@jimpinto.com or view his writings at www.JimPinto.com. Read the Table of Contents of his book, Pinto’s Points, at www.jimpinto.com/writings/points.html.

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Hitachi ProDrive Inverter Software and USB Converter Cable

November 26th, 2009

It would be a bit presumptuous of me to just assume that you are already using Hitachi’s ProDrive Inverter Software, and just “jump in” to telling you about the cable that you use to connect the Inverter to your laptop.

So (insert drum roll here), if you haven’t tried the software, but yet you work with or on Hitachi Inverters , then you really owe it to yourself to try ProDrive.  Look, a lot of my friends, colleagues, and the general riff-raff who sign up on my Facebook account  -  are a little “iffy” when it comes to software.  ANY kind of software can be a little intimidating.  But I’ve got to tell you, the software is a LOT easier to learn and to use, than punching in the  parameters – bending over the digital keypad in a dimly lit noisy environment.  Are you starting to see where I’m coming from?

Plus, come on! Look at the list of possibilties!  You can determine the settings IN ADVANCE, then jump on the Inverter and within seconds upload the parameters – and then your done! Or, you have an existing (working) Hitachi next to one you are replacing.  Download the parameters out of the working unit: Upload the file into the new unit and you are off and running (or fishing, maybe?).

Documentation?  Are you kidding me?  You can make really professional looking and understandable documents for your maintenance department or your customer.  (There are other really cool things you can do like “trending”, but we dont’ have time here.  Maybe later…)

And… it is FREE.  Just download it!  All you need is the cable (Ah, now we finally get to the cable).  And “no”, the cable isn’t a fortune, it is like $120 bucks (but we have been known to negotiate, …gaze into the circle…  … you will not tell everyone).

Now, about that cable…  As you may or may/not know, the cable we now offer for use with ProDrive software is the USB-CONVERTERCABLE. It connects to a USB port on the PC, rather than the RS-232 serial port. The old serial CONVERTER-CABLE  (that plugged into your COM port on your laptop) is discontinued. (Why? Most new laptops don’t even have serial ports any more.)
The instruction sheet that comes with the USB-CONVERTERCABLE lists a web site from which to download the necessary driver. A driver MUST be installed on the PC in order to use this cable. It will not work without a driver! However the driver available from that web site is NOT compatible with Microsoft VISTA operating system. A new VISTA-compatible driver is now available and will be available from this site at some time in the near future.

In the meantime, however, the updated driver can be downloaded from the Hitachi America web site. Please visit www.hitachi-america.us/inverters, then go to the Software Downloads page. You will see the driver listed there. The text on the page explains how to download, extract and install the driver. Note: If you have the old driver installed, it must be uninstalled first. Then you can install the new version. If you are NOT running VISTA, there is no need to update the driver.

Do yourself a favor.  Buy the cable. Download the free software.  Pop the Digital Operator Panel out and remove (remember to save in a safe place) the little double-ended male RJ-45 connector.  Plug the cable in there – plug the USB end of the cable into your laptop and I guarantee you won’t regret spending $120 of your bosses 401K!

Let me know how it turns out!
Timothy

Posted in Inverters, Drives, VFDs | 5 Comments »

Accountability in Corporate America

November 26th, 2009

Did you ever find yourself walking out of some business shaking your head, and found yourself saying “I’ll NEVER buy from those ‘blankety blank” so-and-so’s again!”?  Or, have you ever been in a situation like finding out some “gypsy contractor” scammed your Grandma out of a couple of thousand for a roof job that she didn’t really need and wasn’t ever done?

On a little more grandios scale, what do you think about those companies who recieved millions or even billions of U.S. Government Bail Out Funds, and then paid out millions of our tax dollars in BONUSes???

My feelings are pretty well summed up in an article from ThomasNet Industrial, which states:
“Over the past year, ethical missteps and financial irresponsibility have tarnished public perception of corporate America as a whole. Many businesses now have a serious problem to solve: People don’t trust them. Organizational trustworthiness is a source of competitive advantage, and a lack of trust clearly presents a threat to an organization’s long-term survival. It’s time to reclaim reputations.”

Well Said!  Well Said!

Just out of curiosity, have you (the reader of this blog), ever get ripped off by some well-known company and swear to never do business with them again.  Or, in the bigger perspective, what is your feeling on (now this may be a new term to some) “A C C O U N T A B I L I T Y“??  (Click on the link if this term is unfamiliar.)  And don’t be embarrased – we (even in this world economy) seem to have lost the meaning of this concept somewhere along the way.

My intention on this blog was to keep the Hitachi PLC user community aware of new products, produt developments/enhancements/modifications, etc.  I did not intend for it to become a medium for political viewpoints, but this “Corporate Non-Accountability” has got to stop.

We at Lighthouse PLCs, Inc. strive to be ethical and accountable in all our dealings.  If we have EVER failed you, please let me know.  I’ve always said “You can’t FIX a problem unless you Know the problem exists.”

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LEGACY and EOL Products

November 26th, 2009

I’m in a position (for good or bad) that somehow I turn out to be the focal point of someone’s frustration over a product that they have been using, but suddenly find to be unavailable.  Note that this is not a reference to an empty shelf caused by a distributor or manufacture misjudging demand.  But more precisely, when an item which has been in use for some time, suddenly (or seemingly so,) disappears – I mean dis-ap-pears!

Recently I was asked about “Legacy” and “EOL” products.  First, let’s differentiate the two.  {Some SME (Subject Matter Expert*) may need to jump in here and correct me.}

Both LEGACY and EOL (End Of Life) products are those that are no longer available from the manufacturer.

  • EOL products are products that may have been recently discontinued, but may be still available in the marketplace.  Furthermore, the manufacturer of an EOL product may still offer (sometimes up to 10 years) limited support for its installed base of customers.
  • LEGACY on the other hand (IMNSHO) are (a) discontinued, (b) no longer supported by the manufacturer, and (c) usually harder than hell to find.  (d)Sometimes it is nearly impossible to find so much as a part manual.

This might be a good time to bring up a good point.  Sometimes a manufacturer will have a product that is a “Cash Cow” (if you don’t know what that is, ask the SME who responds to this post.)  The only reason they stop making the “thing” is that the components they use to make the “thing” become unavailable.  So, you savvy readers ask, “Why don’t they just use a new component (like a bigger/harder/stronger/longer/faster‡ – capacitor/transistor/resistor/IC/SMT/THT**)”?

The answer is, (and anyone who builds or prototypes circuit boards will tell you) that if you change one “thing”, it tends to change the dynamics of the whole board.  One little gizmo might make the difference in the unit running or not.   Sad but true.  So if one little gizmo becomes obsolete from some distant (like Texas) plant, it might spell the end for the whole board or assembly or even the entire unit!  So if you are a (savvy) manufacturer, you know this is an unchangeable law of nature(?), and therefore build NEW units with NEWER technology gizmos so that you will be ready for that absolute eventuality that your cash cow is going to fall over and be devoured by the vultures (you can find a compendium of  vulture listing at eBay.com).

It is appropriate to mention “the ripple effect” of EOL and LEGACY products.  Let’s say you have a 1990s vintage PLC with a TCAM (Timer/Counter Access Module  – see, I really DO love the TLAs).  The TCAM gets its power from the PLC (generally the 5vDC intended for the processor).  When the PLC reaches the end of its PLC (Product Life Cycle – get it? ), then the TCAM  is useless.  In other words, pretend you need to replace the TCAM. It fell off and a fork lift ran over it.   Even though the PLC is still functioning, the TCAM may have become a LEGACY unit (along with the PLC). So the end result is the same as if the PLC was a “goner”.  You are going to have to replace the whole thing.

What to do if you discover you have an EOL product?   Realize that everything you use (toaster on up) will eventually become a LEGACY product.  It is going to happen, you can’t change that.   So I propose a two prong approach.

1).  Knowledge.  Try to stay on top of things (easier said than done, I know).  Be aware if/when your favorite 1997 Chrome Kenmore™ Toaster is being discontinued.  Better to find out before-hand, and be able to purchase a replacement element and knob, before you are scrambling to find one on eBay.

(2). Contingency Plan – on critical equipment – you know, those little widgets that – if they fail, your production goes to zero – get a PDF of the User’s Manual NOW.  And ask some SME what component has the worst MTBF (mean time between failures), and lay claim to it now (or add eBayStores.com to your web browsers “favorites”). Dare I say, “Better safe than sorry!”?  And as an appendix to your “contingency plan”, think of what your options are if when that “thing” goes.  What can you replace it with that will do the job and minimize costs (GMROI and all that stuff).

If you are one of the Majority – you will not realize that a critical system (like your PLC) is an EOL product until it is too late (don’t think you’re the Lone Ranger here).  At this point you need to contact the OEM (the people who originally put the machine together) (you can Google them under Italian Toaster (tostapane italiano).  Or, if the OEM is uncooperative/unavailable, talk to your manufacturer or manufactures rep. Try to determine which model will provide the least amount of headaches during the transition, and yet meets the original requirements.  I’ve seen many times when a company installs a replacement system based on what they think they might want to possibly add at a future time if the conditions are right and it’s a Tuesday.  Too late, they realize that they have “shot themselves in the foot” because the new unit won’t do the job the old one did.

It is at this point, that you find out who your real friends are.  I would really like to think that some of you who read this blog, put us in that category (look us up in your “Friends and Family” or “Favorite Five” in your cell phone).  We’re here for you – under “L” hopefully for “Legendary”, not “LEGACY”.

*(TLA’s = Three Letter Acronyms.  As you can tell, I love ‘em!)
‡ (My acknowledgment and Thanks to Daft Punk)
** (IC=Integrated Circuit : SMT=Surface Mount Technology : THT=Through The Hole)

Posted in Legacy Products | 2 Comments »

HITACHI INTRODUCES HIGH PERFORMANCE AC DRIVES

November 26th, 2009

TARRYTOWN, NY, January 12, 2009, Hitachi America, Ltd., Industrial Systems Division, today announced the introduction of the SJ700 Series of inverters. The SJ700 significantly expands on the performance, capabilities and functions of its predecessor, the SJ300.

Hitachi reasserts its technological leadership with an improved sensor-less vector (SLV) control algorithm that enables the SJ700 to develop more than 200% starting torque at 0.3 Hz. The SJ700 can develop 150% torque at 0 Hz, ideal for vertical lift applications, using Hitachi’s unique “0 Hz Domain” open-loop control mode. Hitachi has also greatly simplified the auto-tuning process, making commissioning trouble-free.

A noteworthy enhancement in the SJ700 is Hitachi’s EzSQ (Easy Sequence) built in programming function. It’s like having a PLC built into the inverter! In many cases, the need for a separate PLC can be eliminated. The program is developed on a PC and then downloaded to the inverter using the simple to use EzSQ software provided at no charge.

The SJ700 also incorporates true servo-like position control, offering a low-cost motion control solution. Mated with a general-purpose induction motor with an encoder, the SJ700 is given a position command, speed command, and acceleration/deceleration times. The shaft will move from position A to position B following the defined profile and then maintain the shaft in servo lock status.

Hitachi has also packed many new features into the SJ700. Features such as, but not limited to include, patented micro-surge voltage suppression (to protect the motor winding insulation), advance trip avoidance functions, configurable sink/source logic on I/O, built-in dynamic braking circuit in models up to 30 hp (22 kW) and built-in EMC filter up to 75 hp (55 kW), have been added.

The SJ700 also includes anticipated features, such as built-in RS485 Modbus/RTU communication, and options for other communications networks, such as Ethernet Modbus/TCP, DeviceNet, Profibus and LonWorks. The SJ700 can be configured via the front-mounted keypad or using Hitachi’s ProDrive PC-based software.

The SJ700 carries CE, UL, cUL and c-Tick marks, and is RoHS compliant, exemplifying a true global product. The SJ700 series will be released in stages, with the 250 hp to 500 hp ratings currently available. Other power ranges from 200 hp and down will be released

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