CONTROL SYSTEMS SOLUTIONS FOR PRECISION MOTION TECHNOLOGY. Your First Choice. for Control Systems Solutions

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1 CONTROL SYSTEMS SOLUTIONS FOR PRECISION MOTION TECHNOLOGY Your First Choice for Control Systems Solutions

2 DUFF-NORTON CONTROL SYSTEMS FOR PRECISION MOTION TECHNOLOGY Whether you need a custom turn-key solution, a standalone, or an integration into a legacy system our automated motion control solutions bring together the products and technology that improve your processes and move you into the future through each stage of production. 2

3 DUFF-NORTON CONTROL SYSTEMS TABLE OF CONTENTS DUFF-NORTON CONTROLS Features and Benefits CUSTOM CONTROLS SYNCHRONIZATION CONTROLS VARIABLE SPEED CONTROLS THREE PHASE JOG CONTROLS SINGLE PHASE JOG CONTROLS OPTIONAL ACCESSORIES CONTROL COMPARISON CHARTS Terms of sale POSITIONING CONTROLS PENDANT CONTROLS DIGITAL DISPLAY CONTROLS NOTE Duff-Norton has made every effort to ensure that the information contained in the publication is accurate and reliable. Determining the suitability of our products for specific applications is the user s responsibility. WARNING The equipment shown in this catalog is intended for industrial use only and should not be used to lift, support, or otherwise transport people unless you have written statement from Duff-Norton which authorizes the specific actuator used in your applications as suitable for moving people. Ph: (800) Fax: (704)

4 DUFF-NORTON CONTROL SYSTEMS Why use Duff Norton Controls? We are linear motion experts. We know our linear motion products better than anyone and understand the challenges you face navigating a dynamic marketplace that demands innovative technologies and the agility to contend with a greater need for increased productivity. Our industrial experience combined with the latest controls technologies and our broad assortment of linear motion products make us the ideal partner to work closely with you to design and implement your system solutions. We know how to get the highest performance out of our linear motion products. Through our control solutions we can meet the most advanced industrial lifting, positioning, and transfer demands needed to help you gain a competitive advantage in the global marketplace. 4 Ph: (800) Fax: (704)

5 DUFF-NORTON CONTROL SYSTEMS FEATURES AND BENEFITS Electric control systems support a wide range of applications Duff-Norton engineers a wide range of controls systems, and can provide turn-key solutions for applications ranging from jogging controls to complex automated systems. We offer systems from fractional horsepower sizes up to 200 HP. STANDARD FEATURES All Duff-Norton controls are designed to meet UL508A NEMA enclosures provided for all applications Labeled terminal strip for ease of field connections Motor overload protection Short circuit protection for all control voltages External Main Disconnect Switch (MDS) All wires labeled for quick troubleshooting Electrical schematics provided for all applications BENEFITS Fewer interfaces Better performance One integrated system Turn-key solutions Reduced downtime Increased productivity INDUSTRY EXPERTISE Synchronization controls Positioning controls STANDARD HARDWARE PLCs HMIs VFDs Safety relays STANDARD SOFTWARE PROGRAMMING PLC HMI Variable speed controls Jog Controls Encoders Motor overloads Linear sensors Contactors VFD SERVO Ph: (800) Fax: (704)

6 DUFF-NORTON CONTROL SYSTEMS CUSTOM CONTROLS Custom Controls Duff-Norton realizes no two applications are the same. We work closely with you to understand your application and provide the best possible solution. Control packages can be highly customized to meet your needs. We offer a wide variety of options to meet demanding control requirements. Package options can easily be implemented to best fit your application and provide you with complete turn-key solutions. MANUAL SCREEN 1 Local Message Display RAISE PEDESTAL 2 15 HZ 40 HZ RAISE FORWARD SIDE 15 HZ 40 HZ RAISE PEDESTAL 1 LOWER PEDESTAL 2 50 HZ 60 HZ LOWER FORWARD SIDE 50 HZ 60 HZ LOWER PEDESTAL 1 RAISE SOUTH SIDE LOWER SOUTH SIDE PEDESTAL 1 - FORWARD LEFT 2 - FORWARD RIGHT 3 - AFT RIGHT 4 - AFT LEFT POSITION N.NNN N.NNN N.NNN N.NNN LOAD NNNNN NNNNN NNNNN NNNNN RAISE NORTH SIDE LOWER NORTH SIDE RAISE PEDESTAL 3 15 HZ 40 HZ RAISE AFT SIDE 15 HZ 40 HZ RAISE PEDESTAL 4 LOWER PEDESTAL 3 50 HZ 60 HZ LOWER AFT SIDE 50 HZ 60 HZ LOWER PEDESTAL 4 RAISE LOWER PEDESTALS PEDESTALS MENU SCREEN 2 MANUAL SCREEN 2 FEATURES & BENEFITS Multiple axes of motion AC or DC controls Load sensing Servo applications UL, cul Requirements A large majority of our control panels can be made available with UL or cul certifications. LISTED MET SN160 US Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A OPTIONS Additional Custom Control Options Stack lights HMI pendants Programming ports Quick disconnects Enclosure heaters Explosion proof enclosures Remote pushbutton stations Motor cables Feedback cables Console enclosures NEMA type 4/4x enclosures LED indicators 6 Ph: (800) Fax: (704)

7 DUFF-NORTON CONTROL SYSTEMS SYNCHRONIZATION CONTROLS Synchronization Controls Synchronization controls provide smooth, reliable synchronization of multiple axes of motion. We offer a variety of solutions for synchronizing from two to six axes of motion. Our synchronization packages are designed with reliability and safety in mind. Most importantly, our systems will hold the tolerances set for your specific application. 150 T I/O SCREEN MCR SAFETY RELAY LIMITS OK DRIVE READY FAULT Local Message Display OUTPUTS O0:0 POWER LIGHT O0:1 MCR POWER O0:2 RUN FORWARD O0:3 RUN REVERSE O0:4 SPARE O0:5 DRIVE FREQ 1 O0:6 DRIVE FREQ 2 O0:7 DRIVE ENABLE O0:8 RELEASE BRAKE O0:9 SPARE O0:10 SPARE O0:11 SPARE MAIN MANUAL FAULT INFO INPUTS I0:0 ENCODER CH A I0:1 ENCODER CH B I0:2 SPARE I0:3 SPARE I0:4 E-STOP ACTIVE I0:5 MCR IS ON I0:6 DRIVE READY I0:7 DRIVE FAULT I0:8 SPARE I0:9 SPARE I0:10 SPARE I0:11 SPARE I0:12 BRAKE RELEASED I0:13 SPARE I0:14 SPARE I0:15 SPARE I0:16 SPARE I0:17 SPARE I0:18 EXTEND LIMIT I0:19 RETRACT LIMIT METHODS Synchronization Control Methods Motor starters with motor overload protection Variable Frequency Drives (VFDs) Servo motors with absolute encoders FEEDBACK Synchronization Control Feedback Options Incremental encoders Absolute encoders Potentiometers Linear transducers OPTIONS Ph: (800) Fax: (704) Synchronization Control Options Line reactors/filters for longer motor cable lengths 4-12 inch color touch screens (HMI) Pendant controls Live positioning display Strobe/stack light for motion Additional E-Stops UL or cul certifications LISTED MET US SN160 Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A

8 CONTROL COMPONENTS VARIABLE SPEED CONTROLS Variable Speed Controls Many applications require a variation of speeds during the motion process. Our Variable Speed Controller allows the speed pot to be adjusted between 0% and 100%, even while the application is in motion. We offer preset, selectable speed controls with a choice of three different speeds (25%, 50% and 100%). If custom speeds are desired, they can be easily entered into a numeric keypad as a percentage ranging from 0 to 100%. You have a choice of a pushbutton controller or color touch screen operator for your application. Standard VFD Synchronization Enclosure Dimensions HP HEIGHT WIDTH DEPTH 1/2 3/ / / in 48 in 30 in 8 in 36 in 10 in BENEFITS Variable Speed Control Advantages Allows greater flexibility for motion applications Multiple processes can be achieved with the same equipment by adjusting speeds Eliminates the need for additional equipment for fast or slow processes Eliminates equipment hard starts and stops Prolongs equipment life OPTIONS Variable Speed Controls Options Door mounted Speed Pot adjustable from 0 to 100%. Preset, selectable speeds using a panel mounted selector switch Numeric entry speed using a HMI touch screen UL or cul certifications LISTED MET US SN160 Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A Ph: (800) Fax: (704)

9 CONTROL COMPONENTS POSITIONING CONTROL Positioning Control Positioning applications can be complicated and time consuming. We offer an adaptable range of options to precisely position single or multiple axes of motion. Locations can be easily entered with our numeric entry position controls anywhere along a desired axis and then activated with the Move-To pushbutton. Duff-Norton s versatile, programmable entry position control allows up to five preset positions. Positions can be programmed, stored and changed at any time. MANUAL SCREEN 1 MCR SAFETY RELAY LIMITS OK DRIVE READY Local Message Display FAULT CURRENT POSITION: NNN.NN INCH NNN.NN MM NN.NN NN.NN NN.NN NN.NN NN.NN NN.NN STORE AS SETPOINT 1 STORE AS SETPOINT 2 STORE AS SETPOINT 3 STORE AS SETPOINT 4 STORE AS SETPOINT 5 MOVE POSITION MOVE TO SETPOINT 1 MOVE TO SETPOINT 2 MOVE TO SETPOINT 3 MOVE TO SETPOINT 4 MOVE TO SETPOINT 5 MOVE TO POSITION MANUAL I/O FAULT INFO AUTO STOP FEATURES Standard Position Control Features Panel mounted emergency stop (E-Stop) Labeled terminal block for field connections Fused and shafted Main Disconnect Switch (MDS) Short circuit protection Color touch screen (HMI) NEMA type 12/13 wall mount enclosure Two-channel safety relay Brake relay, if required Illuminated POWER ON indicator UL or cul certifications LISTED MET US SN160 Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A METHODS Position Control Methods Numeric position entry Programmable entry positions Ph: (800) Fax: (704)

10 CONTROL COMPONENTS PENDANT CONTROLS Pendant Controls Duff-Norton pendant controls provide ease of movement around applications. We offer an option of 3, 5, 7, and 9 button pendants. Each pendant control comes standard with an easily accessible emergency stop (E-Stop) button on the pendant. Customize your pendant with selector switches, momentary pushbuttons, indicators, and nameplates to meet your application need. Pendant controls are available to control packages for jogging, synchronization, positioning, and variable speed uses. FEATURES Standard Pendant Control Features Three, five, seven, and nine button pendants Emergency Stop (E-Stop) on pendant Custom Pendant Control Features Selector switches Momentary pushbuttons Indicators Custom nameplates OPTIONS Additional Pendant Control Options LOCAL/REMOTE keyed switch Illuminated E-Stop Customizable pendant cable lengths UL or cul certifications LISTED MET SN160 US Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A Three Button Control Pendant Five Button Control Pendant Nine Button Control Pendant 10 Ph: (800) Fax: (704)

11 CONTROL COMPONENTS DIGITAL DISPLAY CONTROLS Digital Display Controls Positioning applications are becoming increasingly popular in today s industry. Duff-Norton controls provide easy-to-read, live positioning feedback and can be used with encoder, linear transducer, or potentiometer feedback. Scaling a linear application is easy using the panel mounted pushbuttons on the digital display. Digital Display Controls Features Display Resolution inches Input Types Potentiometer (0-10K OHM) Encoder Analog 4-20 ma Power AC and DC models available BENEFITS Standard Benefits of Digital Display Controls Digital display controls can easily be zeroed with the press of a single button Digital display controls offer live feedback for precise positioning Displays can be set up to display up to five decimal positions No need for excitation power supplies for potentiometer applications Additional pull-up resistors are not required for encoder applications OPTIONS Digital Display Controls Options Multiple displays can be used in the same control panel Optional outputs for indicators or alarms Displays can be provided for existing applications UL or cul certifications LISTED MET US SN160 Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A Ph: (800) Fax: (704)

12 CONTROL COMPONENTS THREE PHASE JOG CONTROL Three Phase Jog Control Duff-Norton standard three phase jogging motor controls provide simple operation and reliable service. To start motion simply press and hold the extend or retract pushbutton. To stop motion release either the extend or retract pushbutton. Our three phase jogging motor controls come standard with a power on indicator to inform users that the panel is under power. Standard three phase jog panels include an auxiliary brake relay if fast stopping is required. Labeled terminal strips are included for easy termination of end-of-travel limit switches. Three Phase Jog Controls Specifications Motor Sizes Voltage Enclosure Dimensions Enclosure Mounting Up to 10 HP 460 VAC/3 PH/60 Hz 20"H x 16"W x 6"D Wall Mount FEATURES Standard Features for all Control Boxes Twist-to-release, Illuminated LED EMERGENCY STOP button Labeled terminal block for field connections Fused and shafted Main Disconnect Switch (MDS) Fused 120VAC transformer for control voltage NEMA type 12/13 wall mount enclosure Interlocked reversing contactor Adjustable motor overload Brake relay provided for fast braking applications Illuminated POWER ON indicator Momentary EXTEND/RETRACT pushbuttons OPTIONS Additional Feature Options Illuminated EXTEND/RETRACT pushbuttons MOTOR OVERLOAD indicator Pendant controls Strobe/stack light alarm Maintained operations 230/575V available UL or cul certifications LISTED MET US SN160 Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A Ph: (800) Fax: (704)

13 CONTROL COMPONENTS SINGLE PHASE JOG CONTROL Single Phase Jog Control Duff-Norton offers single phase jogging control panels that meet a wide variety of single phase voltages. All of our control panels come standard with short circuit protection devices as well as adjustable motor overload protection. Single Phase Jog Controls Specifications Motor Sizes Up to 1.5 HP Voltage 110/115/120 VAC/1 PH/ 50/60 Hz 220/230/240 VAC/1 PH/ 50/60 Hz Enclosure Dimensions Enclosure Mounting 16"H x 14"W x 6"D Wall Mount FEATURES Standard Features for all Control Boxes Twist-to-release Illuminated LED EMERGENCY STOP button Labeled terminal block for field connections Door mounted Main Disconnect Switch (MDS) NEMA type 12/13 wall mount enclosure Electrical/mechanical interlocked motor starters Adjustable motor overload Illuminated POWER ON indicator Momentary EXTEND/RETRACT pushbuttons OPTIONS Additional Feature Options Shafted Interlocked MDS Illuminated EXTEND/RETRACT pushbuttons MOTOR OVERLOAD indicator Pendant controls Strobe/stack light alarm Maintained operation UL or cul certifications LISTED MET US SN160 Complies with UL 508A E U L US LISTED C ENCLOSED INDUSTRIAL CONTROL PANEL No. A Ph: (800) Fax: (704)

14 CONTROL COMPONENTS OPTIONAL ACCESSORIES & COMPARISON CHARTS Optional Controls Accessories At Duff-Norton our goal is to provide high quality, reliable control solutions that get your application up and running fast. Our optional accessories include the following: motor cables, VFD cables, sensor cables and cord grips. With minimal time and effort, you ll have all the parts you need to install your new control system. OPTIONAL ACCESSORIES Control Accessory Options Encoder cables Limit switch cable Potentiometer cable VFD cable Motor cable Linear transducer cable Cord Grips Strain reliefs Switches - mechanical/ electrical Comparison Charts Positioning Device Accuracy Encoder Cable Strain Relief Encoder cables are available in four standard lengths 4, 10, 15, and 20 meters. Ask about custom lengths. Variable Speed Device Flexibility Blue Cord Grip Black Brown White Synchronization Device Accuracy Accuracy Flexibility Accuracy Potentiometer Encoder Servo Linear Sensor Device Selector Switch Speed Pot HMI Entry Variable Speed Device Motor Contactors VFDs Servo Motors Motor Control Device 0.60 Positioning / Synchronization Accuracy By Control Type and Feedback Device Accuracy (Inch) Servo - Linear Transducer Servo - Absolute Encoder VFD - Linear Transducer VFD - Encoder 0.25 VFD - Potentiometer Control Type - Feedback Device 0.3 Contactors - Linear Sensor 0.32 Contactors - Encoder Contactors - Potentiometer Note: Accuracy is dependent on speed and type of actuator. The above chart is a general guideline for accuracy Ph: (800) Fax: (704)

15 Glossary HMI Human Machine Interface. Typically a 4 10 inch color touch screen used as a central point for system input. HMIs reduce the need for multiple pushbuttons, indicators, and selector switches. HMIs are extremely versatile and completely customizable. HMIs relay information about a systems I/O, status, status of switches and sensors, as well as specific fault messages. HMIs reduce setup time, troubleshooting, maintenance, and down time. VFD Variable Frequency Drives. VFDs or inverters are used to vary the speed of an electric AC or DC motor. VFDs can use single phase or three phase AC input voltage to drive three phase AC motors. VFDs are extremely beneficial in applications where synchronization, positioning, or variable speed is required. VFDs can be programmed to ramp up, accelerate, or ramp damp, decelerate, over a specific period of time. PLC Programmable Logic Controller. PLCs are controllers that utilize microprocessors to make quick calculations and control peripheral devices. PLCs are often used to read analog inputs as well as encoder inputs. PLCs are flexible and easily allow for process changes as well as equipment upgrades. MDS Main Disconnect Switch. MDSs are used to turn the facility service to a control panel on and off. MDSs can be locked out and tagged out to keep personnel safe while maintenance is being performed. E-Stop Emergency Stop. E-Stops are typically an illuminated or non-illuminated pushbutton used to stop equipment in the case of an emergency. E-Stops are hardwired to disconnect power to an electric motor(s) as well as de-energize control relays. Terminal Strip Terminal strips consist of several individual terminal blocks aligned in a row. Terminal blocks pass wires from one point in a control panel to another point. Terminal blocks are extremely advantageous when wiring field installed devices such as encoders, motors, and switches. Terminal blocks allow wiring of these devices to be terminated at the terminal block as opposed to being terminated at a PLC, VFD, or motor contactor. Panel Meter Panel meters are used to display feedback from a number of input devices. Panel meters are digital displays that provide visual indication of a devices current position. Panel meters use input from potentiometers, linear sensors, encoders, or other analog devices. The signals are then scaled using the panel meter to display position in a meaningful value such as inches or percentage. Types of feedback Incremental encoders Incremental encoders provide digital pulses or counts back to a PLC or VFD. A PLC can be programmed to use encoder pulses to synchronize, position, or vary the speed of an electric motor. Incremental encoders can be mounted on limit switches, reducers, or electric motors. Incremental encoders offer a variety of different pulses per revolution (PPR). Incremental encoders can provide as little one pulse per revolution up to several thousand pulses per revolution. Absolute encoders Absolute encoders work similarly to incremental encoders. Pulses or counts are monitored by a PLC or VFD. Ethernet/IP encoders communicate with a PLC over an Ethernet cable. Unlike incremental encoders, absolute encoders do not lose position or counts when power is cycled. There is no need to reference or home absolute encoders after a power cycle. Potentiometers Potentiometers provide a 0 10 VDC analog output signal. This analog signal can be used by a PLC to scale the position of a device. Potentiometer feedback can be found in rotary or string type devices. Rotary potentiometers can be mounted on limit switches. String type potentiometers are usually mounted to equipment. Potentiometers are useful when an extremely precise degree of accuracy is not needed. Linear Sensors Linear sensors output a 0 10 VDC, or 4 20mA analog output signal. Like a potentiometer this analog signal can be used by a PLC to scale and position or control an electric motor. Depending on the location of the linear sensor in an application, linear sensors provide the highest degree of accuracy. Linear sensors come in a variety of configurations. Rod, magnetic, and non-contact sensors are most frequently used. Load Cells Load cells are feedback devices that detect load. Load cells can detect load in tension, compression, or both tension and compression. Load cells are ideal for applications where load detection or load processes are needed. Load cells like linear sensors come in a variety of configurations such as pancake, donut, or pin style. Types of motion Jogging Jogging motion is the simplest and most common type of motion. Jogging an electric motor can be accomplished in two ways, momentary or maintained. Momentary jogging dictates continual input from a user. The user must press and hold a pushbutton to jog the motor in one direction or the other. Maintained jogging is accomplished through a one-time command such as pressing and releasing a pushbutton. Momentary jogging stops when the user releases a pushbutton. Maintained jogging stops when the user presses the stop pushbutton or the motor reaches a limit switch. Positioning Positioning applications move an electric motor to a specific position. Positioning can be accomplished using an AC, DC, or servo motor along with a feedback device. Servo motors and certain AC and DC motors have encoders mounted on the motor. These devices run in a closed loop to accurately move the electric motor to a desired position. Positioning devices typically use a HMI and input from a user to position the electric motor. Synchronization Synchronization motion allows two or more electric motors to be moved in the same direction together. Synchronization motion is most useful in applications that cannot be mechanically coupled. Synchronization provides a means to electrically couple the electric motors. Synchronization uses positional feedback from multiple motors to hold a tolerance between the motors. Synchronization motion uses multiple types of feedback as well as motor control devices. Variable Speed Variable speed motion allows an electric motor to be moved at various speeds. Variable speed applications are common in applications where the manufacturing process changes frequently. Variable speed applications are useful in applications where the motor needs to start slowly and ramp up to speed. HMIs, speed pots, and selector switches can be used to vary the speed of an electric motor. HMIs provide the most flexibility by allowing the user to Ph: input (800) a desired speed. Fax: (704)

16 135 YEARS OF POSITIONING & PROCESS SOLUTIONS Since 1883, Duff-Norton has been at the forefront of precision motion technology. Providing a continued commitment to leading edge manufacturing and highest quality engineered products for the most advanced industrial lifting, positioning and transfer needs for our customers worldwide. Motion technology today is expected to lift, move and precisely position heavy loads, often under extreme or adverse conditions. Whether it s creating motion to twist and pivot, open and close or keeping a production line moving, Duff-Norton has the right solution to meet the demand. Our systems can be found in industries ranging from aluminum, steel, agriculture, pharmaceutical, material handling, energy, food and beverage, to automated machinery Pioneer Ave. Charlotte, NC Phone: (704) (800) Fax: (704) duffnorton@cmworks.com Duff-Norton ISO 9001: QM Duff-Norton, Inc., Columbus McKinnon Engineered Products. All Rights Reserved. PB-CNTL-01 03/18