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Accessible Automation Helps Small Utilities Modernize Operations

Morgan Collett — Wed, 15 Apr 2026 12:02:13 +0000

A wastewater treatment utility is moving away from aging control hardware by replacing specialized components with easy-to-use programmable logic controllers.

Like many small utilities throughout the country, the Harvest-Monrovia Water & Sewer Authority in Alabama was faced with supporting an aging mix of control technologies. Wesley Benefield of RTUDirect wrote this article for Automation.com April 2026, titled Case Study: Small Municipality Streamlines and Standardizes Wastewater Treatment Sites with PLC Hardware, describing how the team developed a standardized, PLC-based control architecture that simplifies maintenance, reduces long-term risk, and positions the utility for decades of scalable growth.

Subdivision Wastewater Treatment Systems

The utility operates numerous decentralized wastewater sand filters, each serving individual housing developments. These systems rely on local septic tanks at each house for primary treatment, followed by centralized sand filtration, UV disinfection, and subsurface dispersal.

To maintain reliability, wastewater systems evolve cautiously, and historical designs emphasized robustness over real-time data access. This meant relying on float switches, basic flowmeters, and manual overrides for a long duration, before implementing digital communication and controls.

Over time, the utility integrated a patchwork of specialized circuit board controllers (originally intended for HVAC applications), legacy PLCs and HMIs, and other elements. While functional, this approach became increasingly fragile as components became obsolete, documentation disappeared, and experienced personnel retired. The lack of standardization made upgrades and troubleshooting cumbersome and introduced risk.

Moving to Open Hardware

To address these challenges, the utility engaged industry veteran Wesley Benefield, PE, to help define a modern control strategy centered on simplicity, openness, and long-term support. The resulting solution standardized on AutomationDirect BRX-series stackable micro brick PLCs paired with C‑more human-machine interface (HMI) touchscreens. Key selection criteria included free programming software, strong training resources, flexible I/O expansion, long product lifecycles, and fast, transparent parts availability.

The PLC platform’s modular and stackable design supports tailoring each installation to its specific number of level floats, pumps, and distribution zones, while preserving a common core architecture. Auto-detection of I/O, tag-based programming stored on the controller, and ample onboard and SD-card memory enable built-in data logging and straightforward diagnostics, while integrated web server capabilities and broad protocol support simplify SCADA integration.

The migration of hand/off/auto (HOA) functionality from hardwired selector switches to the HMI is one of the most notable design shifts. This reduced cabinet complexity and cost, while improving flexibility. The touchscreen interface also provides richer operational statistics, detailed diagnostics, and intuitive commissioning tools—valuable for both installers and operators.

Remote monitoring is handled via low-bandwidth cellular connectivity, replacing an earlier radio-based SCADA system that had reliability issues. This approach supports telemetry, alarming, and analytics today, while remaining scalable for future needs.

Ready for Growth

With roughly half of its 15 sand filter sites already upgraded, the utility now has a repeatable and contractor-friendly automation standard. As regional growth continues, the modernized control platform ensures that wastewater infrastructure can expand reliably and sustainably.

While those in the industry can appreciate the system’s elegant design, the public will ideally never have to think about it. Residents can maintain the practical assumption that, like magic, water comes out of the tap and disappears down the drain to … somewhere.

Check out the complete AutomationDirect portfolio, to find the products you need for creating efficient and easily-supported automation projects of any type.

BLOCK Power Advanced Series Power Supplies with Battery Control / UPS and More

Morgan Collett — Wed, 15 Apr 2026 11:58:44 +0000

April 15, 2026 – AutomationDirect now offers BLOCK DC uninterrupted power supply (UPS) devices and modules which provide low-cost solutions for applications requiring continuous equipment operation. The Power Advanced series offers a switching power supply and a battery control module in one unit for optimal battery management, along with a UPS system to monitor the battery for low power conditions. New BLOCK battery control modules work with 24 VDC power supplies of any brand to easily add a reliable UPS to existing systems.

The BLOCK buffer control module uses Electrolytic Double Layer Capacitors (EDLC) to monitor, control, and provide backup power to a unit without using traditional battery control modules and batteries. This unit is ideal for applications requiring short-duration power bridging with maintenance-free operation and an extended lifespan. The BLOCK battery storage modules provide an enclosed compartment where a battery can be stored. Combined with a power supply and battery control module, these storage devices build a complete UPS system that will quickly switch from standby to full power, maintaining grid reliability. The BLOCK Power Mini series power supplies offer performance and reliability without the higher cost of full-featured power supplies. These robust power supplies feature a compact form factor, excellent transient voltage protection, and are adaptable for a wide range of applications.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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Supplier Profile: Penn Union

Morgan Collett — Wed, 08 Apr 2026 10:27:11 +0000

We all learned at an early age that electricity powers the world. The team behind Penn-Union learned how to harness that power, creating electrical connection solutions that perform even in some of the most challenging applications across industries such as commercial construction, utilities, data storage, telecom and aerospace.

Founded in 1928, Penn-Union operates a fully integrated production facility and office in Edinboro, Pennsylvania. These headquarters feature a non-ferrous green sand foundry, a diverse machine shop, a design and engineering department and an in-house UL Certified test laboratory. The company has been privately owned since 1994, and during this time, it has systematically strengthened design and manufacturing capabilities through sustained capital investment, strategically aligned acquisitions and key strategic partner alliances.

“We take pride in our longevity and the excellent reputation we have built for nearly a century in this business,” said Brian Cullen, Group President. “At Penn-Union, our highly skilled, U.S. – based team designs, manufactures and sells more than 30,000 connector variations. If a solution isn’t in our catalog, we can engineer and make it.”

That level of flexibility makes it easy for customers to do business with Penn-Union. Combined with a strong customer focus, the company continues to expand its product offering while driving gains in manufacturing efficiency, productivity and quality assurance.

Precision with Every Pour

“Our in-house foundry is one of the key advantages of our manufacturing processes,” Cullen said. “It’s one of the main reasons we can efficiently produce such a wide variety of high-quality electrical connectors and components without sacrificing precision or reliability.”

The Penn-Union foundry uses advanced induction melting technology to heat copper, bringing it to a molten state ideal for casting. Once molten, the copper is carefully poured into precision-engineered molds.

Continued investment in the foundry ensures full control over production and quality. “At a time when many manufacturers rely solely on overseas casting sources, our U.S.-based foundry delivers clear advantages in responsiveness, reliability, and consistency,” Cullen said.

By leveraging specialized equipment, Penn-Union can combine multiple manufacturing operations. Examples include:

Computer-controlled automated molding equipment allows quick pattern changes for both short and long production runs of cast copper and aluminum components
Cold-forming technologies such as extruding, upsetting, coining and piercing ensure dimensionally consistent, high-strength products like copper split bolts, press-ons and silicon bronze hardware, among others.

In-house Testing and Quality Control

Penn-Union manufactures a wide range of compression and mechanical electrical connectors constructed from high-grade aluminum and copper for maximum conductivity. Products are designed to meet a variety of industry standards and test criteria, including UL, CSA, ANSI, NEMA and IEC, along with individual customer specifications. Color-coded compression connectors are certified for installation using industry-standard tools. The in-house UL Certified test laboratory enables more efficient certification, listing and recognition processes.

“Quality is central to every operation, and every one of our products undergoes thorough electrical and mechanical evaluation,” said Jim McWilliams, Quality Systems Manager.

Penn-Union’s ISO 9001:2015 registration reflects this commitment to rigorous quality management.

Penn-Union at AutomationDirect

AutomationDirect offers a complete portfolio of Penn-Union power connection and distribution solutions. Supporting copper and aluminum conductors in multiple configurations, the UL-listed lineup includes modular power distribution blocks (APDB and ASRB series), mechanical lugs, neutral bars, compression lugs and more.

The most recent additions to the product catalog include split bolt connectors, power bars and service post connectors for a wide range of power distribution applications.

Split bolts deliver a secure, long-lasting connection for two conductors and are engineered to handle multiple wire gauges and material combinations, including CU and AL.
Aluminum, pre-insulated power bars and in line splicers/reducers are engineered to handle two to four conductors in AL or CU configurations, providing broad compatibility, rugged construction and dependable insulation.
Bronze service post connectors deliver outstanding conductivity thanks to their premium high copper wrought alloy construction. They create a solid, dependable link between copper cables and steel structures, bus bars, transformers or electrical enclosures.
Oxide inhibitors, used in mechanical and compression connectors, are specially formulated to prevent oxidation and corrosion before they begin, ensuring long-term electrical reliability and performance.

Connecting to Tomorrow

Customers rely on Penn-Union products to perform consistently in the most demanding applications. To earn that trust and reliance, the company looks at what customers need now and what they may need as industries and technology evolve.

“For nearly a century, Penn-Union has been a trusted provider of electrical power and grounding connectors, continuously expanding our product portfolio and capabilities to meet evolving customer needs,” Cullen said. “Whatever the electrical connection demands, we provide the performance and reliability our customers depend on today and tomorrow.”

New AchieVe Pressure Switches at AutomationDirect

Morgan Collett — Wed, 01 Apr 2026 13:46:38 +0000

April 1, 2026 – AutomationDirect now offers AchieVe LPPS and S18-1C mechanical pressure switches which deliver rugged, reliable pressure sensing for demanding industrial applications. Built with durable brass housings and simple, secure setpoint adjustment, these switches provide dependable relay outputs without the need for external contactors or interposing relays.

The LPPS series supports pressure ranges up to 3000 psig and features a 5A SPDT relay output at 125 VAC (3A at 30 VDC). Models are offered with 1/8 or 1/4 in. NPT male process connections and a mechanical setpoint adjustment with locking screw, all in a rugged housing rated for NEMA 4 and 13 environmental protection.

The S18‑1C series is designed for pressure ranges up to 120 psig and features a high‑capacity 10A SPDT relay output at 125/250 VAC (5A at 30 VDC). These switches include a simple thumbwheel for fast, precise setpoint adjustment, a 1/8 in. NPT male process connection, and rugged construction that ensures consistent performance across a wide ‑20 to 220°F operating range.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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Channellock Linesmans & Locking Pliers LX

Morgan Collett — Wed, 01 Apr 2026 13:46:28 +0000

April 1st, 2026-AutomationDirect has added CHANNELLOCK® American-made pliers and tool sets are engineered for tradespeople who demand reliability on every job. V-jaw pliers offer superior contact on pipes, tubing, and round stock thanks to their unique geometry. With laser-hardened teeth, PERMALOCK® fasteners, and a slip-resistant undercut tongue-and-groove design, these pliers deliver extreme holding power. For heavy-duty cutting, CHANNELLOCK lineman’s pliers featureXtreme Leverage Technology (XLT™), which places the rivet closer to the cutting edge for dramatically reduced cutting effort. Precision-machined knife-and-anvil edges ensure perfect mating and long-term cutting efficiency. New locking pliers offer curved-jaw and long-nose variants designed for fast, one-handed operation. The extended-release lever prevents pinch points while the epoxy-resin coating boosts rust resistance—ideal for metalworking, automotive, and fabrication environments.

Additionally, CHANNELLOCKend cutting pliers are engineered with XLT™ technology and laser-treated cutting edges for cleaner, stronger cuts through nails, wire, and fasteners. New cable cutting pliers provide exceptional shearing force, easily handling up to 4/0 aluminum and 2/0 copper cable—making them indispensable for electricians and automotive technicians. Rounding out the newest additions are the long reach pliers, delivering extended access in tight or recessed workspaces with precision gripping or cutting performance. Snap ring pliers and multiple technician’s tool sets are also available, offering turnkey tool assortments with professional-grade versatility.

About AutomationDirect:

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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di-soric Ultrasonic Sensors

Morgan Collett — Wed, 01 Apr 2026 13:46:11 +0000

April 1st, 2026-AutomationDirect now offers di-soric 8, 12, 18, and 30mm tubular and 12mm rectangular ultrasonic proximity sensors that are designed for contactless distance measurement and offer IO-Link with ISDU support, a rugged nickle plated brass construction, high IP67 protection ratings, and sensing distances up to 6,000mm. ISDU (Indexed Service Data Unit) provides on-demand exchange of parameter data (i.e., identification, configuration, diagnostics) between the IO-Link master and the connected device to ensure that measuring tasks and tasks such as avoiding influence from several sensors are possible in one application. ISDU allows access to specific settings using index/subindex addresses, enabling parameter modification, such as changing sensor thresholds or device diagnostics, without disrupting real-time operation. Output options include N.O./N.C. selectable outputs with push-pull NPN or PNP configurations or 0-10 VDC or 0/4-20 mA analog outputs. 4-pin M8 or M12 quick-disconnect terminations provide for quick and easy wiring and right-angle beam adapters are available for beam adjustments.

About AutomationDirect:

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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Ironhorse ACM AC Drives and ACN EtherCAT Communications Modules from AutomationDirect

Morgan Collett — Wed, 25 Mar 2026 12:43:51 +0000

March 25, 2026 – AutomationDirect has added IronHorse ACM Series AC drives provide basic V/Hz and sensorless vector control for low-horsepower motors when only single-phase power is available.

These VFDs accept a 120 VAC or 230 VAC single-phase power source and control motors from 1/8 to 3 horsepower. 5 digital inputs, 2 relay outputs, 2 analog inputs, and 1 analog output are standard, along with dynamic braking circuitry. These drives support advanced features normally only found on more expensive drives, such as PID control, 2-motor control, fire mode, momentary power loss restart, and can be password protected to prevent unauthorized changes to the configuration. Programming can be accomplished through the built-in keypad (remote keypad optional) or with the free VFD Suite software. If you are short on space, these drives support zero-stack installation and don’t require spacing between adjacent ACM drives.

Another addition to the IronHorse drives family has been added as part of this launch. The ACN‑ECAT module enables any IronHorse ACN series drive to communicate effortlessly over EtherCAT for faster, more integrated motion control.

Shaviv Deburring Tools, Sets and Accessories from AutomationDirect

Morgan Collett — Wed, 25 Mar 2026 12:43:47 +0000

March 25, 2026 – AutomationDirect has added Shaviv deburring tool sets offer complete turnkey solutions for professionals who need multi-material capability right out of the box. The premium 21-piece (154-00024) and 12-piece sets (154-90085) feature ergonomic universal handles, extendable blade holders, and a comprehensive selection of rotating B- and E-series blades—ensuring you have the right tool for straight edges, hole edges, cross-holes, and more. For high-demand operations, the expanded Heavy-duty and Mango IIB/IIE tool sets provide advanced ergonomics in compact form factors that accept blades directly, which is ideal for tight spaces and repetitive use. These configurations offer increased control and quick blade changes while maintaining rugged reliability.

Shaviv tools offer high-speed steel blades with excellent durability or TiN-coated blades that provide superior wear resistance for stainless steel and other hard metals. F-series countersinkers feature a conical cutting geometry, creating a clean chamfer while removing burrs from drilled or punched holes. Specialty R10 blades have a scraping geometry designed for deburring straight edges and sheet metal in both stroke directions. The Ceramix Q10 ceramic deburring tool is engineered specifically for delicate plastic and wood surfaces with a retractable ceramic blade that stays sharper longer and fits standard utility knife handles.

Define Instruments Panel Meters & Signal Conditioners

Morgan Collett — Wed, 25 Mar 2026 12:43:43 +0000

March 25, 2026-AutomationDirect now offers Define Instruments digital panel meters, signal conditioners, and temperature transmitters that feature versatile measurement options and easy configuration. The Merlin series digital panel meters accept current, temperature, voltage, potentiometer, and pulse inputs and provide advanced scaling, linearization, and optional analog retransmission or relay outputs. A bright LED display, IP65 front rating, and USB-powered configuration via Define’s toolbox software make the Merlin series a versatile solution for process monitoring and control.

The LPI610 series loop-powered digital panel meter features a compact, front-mount display that requires virtually no space behind the panel. It offers a high-resolution LCD with selectable units, simple pushbutton setup, built-in diagnostics, and an IP65 front rating, making it a clean, reliable option for 4-20 mA loop indication.

The Javelin series loop-powered signal conditioner supports a wide range of input types and provides a standard 4-20 mA output for easy integration. This DIN-rail mounted conditioner features a slim 12.5 mm profile that maximizes cabinet space.

TM series signal conditioners provide universal input support with isolated voltage/current outputs or loop-powered 4-20 mA operation, depending on the model. Their straightforward software configuration, flexible power options, and narrow DIN-rail housings simplify integration into dense control panels.

Sentry series signal conditioners feature universal inputs, DIN-rail mounting, dual relay outputs with optional analog retransmission, and a convenient 4-digit LED display for real-time monitoring and fault indication. With selectable modes for heating, cooling, alarm, and pump-duty control, the Sentry series delivers process controller capability in a compact form factor.

TM-2HL series head-mount temperature transmitters provide accurate 4-20 mA outputs for RTD, thermistor, and thermocouple sensors in standard DIN Form B heads. These loop-powered modules offer fast response, low drift, configurable failure modes, and USB programming for quick commissioning.

About AutomationDirect:

In business since 1994, AutomationDirect is a distributor offering thousands of industrial automation products for electrical control systems, including PLCs, operator interfaces, AC drives, motors, stepper systems, sensors, motor controls, enclosures and more. Their prices are typically well below the list price of more traditional automation companies because of their business model and focus on efficiency, and the majority of their products are stocked for fast shipping. Plus, get free two-day delivery on orders over $49; some limitations apply. For more information and the most current pricing on products contact them at 800-633-0405 or visit https://www.automationdirect.com/

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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More Datalogic Smart-VS Vision Sensors from AutomationDirect

Morgan Collett — Wed, 25 Mar 2026 12:43:39 +0000

March 25, 2026-AutomationDirect now offer Datalogic Smart-VS vision sensor family models with expanded features. The new Smart-VS Plus sensor includes all the features of the standard Smart-VS sensor, including Ethernet communication and several I/O points, but adds additional object classifications for a total of 3 classes, which is useful when Good/No Good/No Object tests are needed. The Smart-VS Plus imager supports up to 20 stored images, and the operating range is expanded to 50-400 mm.

Datalogic’s most advanced vision sensor, the Smart-VS EVO, includes everything the Smart-VS Plus offers, with support for a 6-class classification, including anomaly detection, and the imager stores up to a total of 50 images. It provides the same long-range operating distance (50-400 mm) but includes an additional output for a total I/O count of 4 outputs and 2 inputs.

These new sensors come with a 3-year warranty and boast the same easy setup as the basic Smart-VS sensor, using a web-based GUI that requires no specialized training or experience.

About AutomationDirect:

Editorial Contact: Tina Gable
Phone: 678-455-1845
Email: tgable@automationdirect.com
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