C04_Attachment 3_SOW Appendix_1232SA27Q0004.pdf

USDA ARS Cotton Ginning Research Unit

Stoneville, MS

Micro Gin Controls with PLC and HMI Supplemental Information

Table of Contents

Appendix………………………………………………………………………….……2

Cotton Ginning Research Unit site map………………………………………7

Gin Lab layout…………….......................………………………………………8

Existing layout of Building 26..........................................……………...9

Machine layout in Building 26......................................…………………………….10

Micro Gin Pre-Cleaning Machine Selector Options Scheme………….12

Micro Gin Controls with Programmable Logic Controllers (PLC) and Human Machine Interface (HMI)

Appendix

Contents:

1 Installation 2 Motors 3 Inputs and Outputs (I/O) 4 PLC and HMI

1 – Installation:

a) The USDA ARS micro gin facility is a research laboratory. As such, the facility must remain functional to the degree possible to meet various research requirements.

Contractor will be required to perform installation of supplied equipment and associated materials in such manner as to minimize the down time of the micro gin research facility.

b) Contractor is responsible for providing 120 and 240 volt single-phase from existing 45 kVa transformer at east end of building 26 as required for new configuration.

2 – Motors:

a) All motors provided by USDA ARS. All are either on-hand or new.

b) Table 1 is a listing of all motors associated with the new micro gin configuration.

c) Table 2 indicates which motors require starters vs. variable frequency drives.

d) Motor starting sequence is listed in Table 1.

Table 1

Mtr Machine Mtr

HP

Mtr

RPM

Mtr FLA NP Mtr V

1 Seed Blower 5 3490 6.8 440 2 Battery Condenser 2 1770 2.8 460 3 Mote Condenser 2 1770 2.8 460 4 #1 Lint Cleaner 5 1740 6.5 460 5 #2 Lint Cleaner 7.5 1750 9.4 460 6 #3 Lint Cleaner 7.5 1765 8.9 460 7 #1 Lint Cleaner Feed Works 2 1770 2.8 460 8 #3 Lint Cleaner Feed Works 3 1765 4.11 460 9 Lint Cleaner Exhaust Fan 10 1770 13.5 460

10 Mote Fan 7.5 3491 9.3 460 11 Gin Stand Brush 2 1760 3.5 460 12 Gin Stand Mote Wiper 0.5 1725 1 460 13 Gin Stand Saw 25 1760 32 460 14 Gin Stand Agitator 3 1760 4.2 460 15 Extractor Feeder Extracting Section 2 1760 3.5 460 16 Extractor Feeder Cylinder Cleaner Section 2 1760 3.5 460 17 Extractor Feeder Feed Rollers 0.5 1735 0.8 460 18 Conveyor Distributor 0.75 1700 1.31 460 19 Inclined Conveyor 1 3505 1.5 460 20 Gin Separator & Vacuum Feeder 3 1750 3.2 440 21 Gin Separator Fan A & B 10 1710 13.4 460 22 Impact Cylinder Cleaner 5 1745 6.4 460 23 Impact Cylinder Cleaner Separator 2 1740 3.2 440 24 TrashMaster Cylinder Cleaner 10 1750 12.4 460 25 TrashMaster Cylinder Cleaner Separator 2 1740 3.2 440 26 Stick Machine 10 1750 12.4 460 27 Stick Machine Separator 2 1740 3.2 440 28 Inclined Cylinder Cleaner 10 1750 12.4 460 29 Inclined Cylinder Cleaner Separator 2 1740 3.2 440 30 Horizontal Cylinder Cleaner Trash Vacuum (Future) 2 1770 2.8 460 31 Horizontal Cylinder Cleaner Trash Conveyor (Future) 1 1770 1.5 460

32 Horizontal Cylinder Cleaner (Future) 10 1750 12.4 460 33 Impact Cylinder Cleaner Separator Fan 10 1710 13.4 460 34 TrashMaster Cylinder Cleaner Separator Fan 10 1710 13.4 460 35 Stick Machine Separator Fan 10 1710 13.4 460

36 Inclined Cylinder Cleaner Separator Fan 10 1710 13.4 460 37 Tower Drier 1B Separator 2 1740 3.2 440 38 Tower Drier 2B Separator 2 1740 3.2 440 39 Tower Drier 1B Burner Fan 10 1710 13.4 460 40 Tower Drier #2B Hot Air Pull Fan 30 1765 37 440 41 Tower Drier 1A Separator 2 1740 3.2 440 42 Tower Drier 2A Separator 2 1740 3.2 440 43 Tower Drier 1A Burner Fan 10 1710 13.4 460 44 Tower Drier #2A Hot Air Pull Fan 30 1775 35.8 440 45 Feed Control Bottom Vacuum Feeder 3 1740 3.83 460 46 Feed Control Separator and Top Vacuum Feeder 3 1740 3.83 460 47 Unloading Fan 30 1770 38 460 48 Feed Control Drive 0.5 1760 0.86 460

Table 2

Mtr Machine Starter

Size

New- On

Hand Starter Type VFD 1 Seed Blower 0 New DOL/Non-reversing 2 Battery Condenser 0 New 480V/460V VFD New 3 Mote Condenser 0 New 480V/460V VFD New 4 #1 Lint Cleaner 0 New 480V/460V VFD On Hand 5 #2 Lint Cleaner 1 New 480V/460V VFD On Hand 6 #3 Lint Cleaner 1 New 480V/460V VFD New 7 #1 Lint Cleaner Feed Works 0 New 480V/460V VFD New 8 #3 Lint Cleaner Feed Works 0 New 480V/460V VFD On Hand 9 Lint Cleaner Exhaust Fan 0 New 480V/460V VFD New

10 Mote Fan 1 New DOL/Non-reversing 11 Gin Stand Brush N/A On Hand 480V/460V VFD On Hand 12 Gin Stand Mote Wiper N/A On Hand 480V/460V VFD On Hand 13 Gin Stand Saw N/A On Hand 480V/460V VFD On Hand

14 Gin Stand Agitator N/A On Hand 480V/460V VFD On Hand 15 Extractor Feeder Extracting Section N/A On Hand 480V/460V VFD On Hand 16 Extractor Feeder Cylinder Cleaner Section N/A On Hand 480V/460V VFD On Hand 17 Extractor Feeder Feed Rollers N/A On Hand 480V/460V VFD On Hand

18 Conveyor Distributor 00 New 480V/460V VFD New 19 Inclined Conveyor 00 New 480V/460V VFD New 20 Gin Separator & Vacuum Feeder 0 New DOL/Non-reversing 21 Gin Separator Fan A & B 1 New DOL/Non-reversing 22 Impact Cylinder Cleaner 0 New DOL/Non-reversing 23 Impact Cylinder Cleaner Separator 0 New DOL/Non-reversing 24 TrashMaster Cylinder Cleaner 1 New DOL/Non-reversing 25 TrashMaster Cylinder Cleaner Separator 0 New DOL/Non-reversing 26 Stick Machine 1 New DOL/Non-reversing 27 Stick Machine Separator 0 New DOL/Non-reversing 28 Inclined Cylinder Cleaner 1 New DOL/Non-reversing 29 Inclined Cylinder Cleaner Separator 0 New DOL/Non-reversing 30 Horizontal Cylinder Cleaner Trash Vacuum (Future) 0 Future DOL/Non-reversing 31 Horizontal Cylinder Cleaner Trash Conveyor (Future) 0 Future DOL/Non-reversing 32 Horizontal Cylinder Cleaner (Future) 1 Future DOL/Non-reversing 33 Impact Cylinder Cleaner Separator Fan 1 New DOL/Non-reversing 34 TrashMaster Cylinder Cleaner Separator Fan 1 New DOL/Non-reversing 35 Stick Machine Separator Fan 1 New DOL/Non-reversing 36 Inclined Cylinder Cleaner Separator Fan 1 New DOL/Non-reversing 37 Tower Drier 1B Separator 0 New DOL/Non-reversing 38 Tower Drier 2B Separator 0 New DOL/Non-reversing 39 Tower Drier 1B Burner Fan 1 New DOL/Non-reversing 40 Tower Drier #2B Hot Air Pull Fan 3 New DOL/Non-reversing 41 Tower Drier 1A Separator 0 New DOL/Non-reversing 42 Tower Drier 2A Separator 0 New DOL/Non-reversing 43 Tower Drier 1A Burner Fan 1 New DOL/Non-reversing 44 Tower Drier #2A Hot Air Pull Fan 3 New DOL/Non-reversing 45 Feed Control Bottom Vacuum Feeder 0 New DOL/Non-reversing 46 Feed Control Separator and Top Vacuum Feeder 0 New DOL/Non-reversing 47 Unloading Fan 3 New DOL/Non-reversing 48 Feed Control Drive 00 New 480V/460V VFD New

3 – Inputs and Outputs (I/O):

a) Discrete Inputs - 230

b) Discrete Outputs - 130

c) Analog Inputs – 26

d) Analog Outputs – 20

e) Contractor to provide 20-25% spare I/O capacity.

4 – PLC and HMI:

a) PLC and HMI(s) to be mounted in stand-alone consolet with plinth.

b) Consolet to be of NEMA 4 steel construction, similar to Hammond Manufacturing Series 2CLC (source, data sheet tENH-142, www.automationdirect.com).

c) Actual dimensions of consolet to be determined by size and physical layout of PLC, number and dimensions of HMIs and associated electrical controls and devices.

d) Consolet top panel to include minimum three (3) hardwired devices, one red-lighted Emergency Stop PB, one key-llock On/Off switch and one green-lighted Manual Re-Set PB.

e) The following exemplifies acceptable PLC manufacturers. Substitutions are acceptable but must be pre-approved by client.

1) Schneider M340

2) Allen Bradley COMPACTLOGIX 5380

3) Siemens SIMATIC S7-1500

4) Omron NX1P2

5) Automation Direct BRX

f) There is no preference for supply of HMI(s). HMI(s) must meet U.S. Government requirements for source. Unit(s) shall be of the size and resolution to clearly display fifty (50) motor start/stop stations in one screen.For example25” panel at minimum Full HD 1920 x 1080 resolution.

FullSupplier to determine minimum number of HMI units necessary to satisfy client requirements.

5 – Starters:

a) The following is the accepted list of non-reversing NEMA 1 type with electronic starter manufacturers, not in any order of preference. Substitutions are acceptable but must be pre-approved by client.

1) ABB Electrification U.S.

2) Schneider Electric

3) Eaton

4) Siemens

5) Rockwell Automation (Allen Bradley)

6) Mitsubishi Electric

7) Fuji Electric

8) General Electric

b) The following is the accepted list of Variable Frequency Drives in order of preference. Substitutions are acceptable but must be pre-approved by client.

1) Schneider Altivar ATV340

2) Eaton Power XL DX1

3) Mitsubishi FR-A800

6-TTime Frame and Delivery::

a) PLC and HMI delivery and installation complete by April 1, 2027.

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Micro Gin Pre-Cleaning Machine Selector Scheme

ID Machine A 1st Stage Tower Drier B 2nd Stage Tower Drier C Inclined Cylinder Cleaner D Stick Machine E TrashMaster Cylinder Cleaner F Impact Cleaner From/To refers to material flow direction G Overflow Separator

Valve Scheme Valve Scheme ID From To

1 1 Feed Control 2 1A Inlet 1A Tower Drier Separator 3 1B B side of valve 25 4 2 Discharge 1B Tower Drier Separator 5 2A A side of valve 25 6 2B B side of valve 3 7 3 Inlet 1B Tower Drier Separator 8 3A Outlet of valve 26 9 3B B side of valve 2

10 4 Discharge 2B Tower Drier Separator 11 4A Inlet of valve 5 12 4B B side of valve 11 13 5 A side of valve 4 14 5A Inlet of valve 6 15 5B B side of valve 14 16 6 A side of valve 5 17 6A Inlet of valve 7 18 6B B side of valve 17 19 7 A side of valve 6 20 7A B side of valve 8 21 7B B side of valve 20 22 8 A side of valve 9 23 8A A side of valve 19 24 8B A side of valve 7 25 9 Inlet of valve 29 26 9A Outlet of valve 8 27 9B B side of valve 24

Draft

Valve Scheme Valve Scheme ID From To

28 10 Outlet of valve 25 29 10A A side of valve 12 30 10B A side of valve 11 31 11 Separator over Inclined Cylinder Cleaner C 32 11A B side of valve 10 33 11B B side of valve 4 34 12 Inlet of valve 13 35 12A A side of valve 10 36 12B B side of valve 21 37 13 Outlet of valve 12 38 13A A side of valve 15 39 13B A side of valve 14 40 14 Separator over Stick Machine D 41 14A B side of valve 13 42 14B B side of valve 5 43 15 Inlet of valve 16 44 15A A side of valve 13 45 15B B side of valve 22 46 16 Outlet of valve 15 47 16A A side of valve 18 48 16B A side of valve 17 49 17 Separator over TrashMaster E 50 17A B side of valve 16 51 17B B side of valve 6 52 18 Inlet of valve 19 53 18A A side of valve 16 54 18B B side of valve 23 55 19 Outlet of valve 18 56 19A A side of valve 8 57 19B A side of valve 20 58 20 Separator over Impact Cleaner F 59 20A B side of valve 19 60 20B B side of valve 7 61 21 Discharge of Inclined Cylinder Cleaner C 62 21A A side of valve 26 63 21B B side of valve 12 64 22 Discharge of Stick Machine D 65 22A A side of valve 27 66 22B B side of valve 15

Draft