Download CENTERLINE® Intelligent Motor Control Centers

CENTERLINE® Intelligent Motor Control Centers
Considerations for Designing an Intelligent Motor Control Center
Rev 5058-CO900E
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Agenda
IntelliCENTER® Technology
What is it and how does it improve the design & operation of an MCC?
Embedded Systems & Intelligent Motor Control
Software & Controller Integration
IntelliCENTER MCC Return on Investment Case Study
How does it lower the installation & operating costs of an MCC?
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Overview
 Integrated, preconfigured
network infrastructure
 Order specific, customized
support materials
 Preconfigured user interface
software for monitoring,
diagnostics and configuration
Leverage IntelliCENTER to enable & strengthen enterprise solutions
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Overview
 Faster Integration

Network is preconfigured (node number, IP address,
baud rates, functionality verified)
 Faster installation compared to hardwired I/O
 Control and diagnostics

State of the art intelligent motor controls provide crucial
feedback from motors
 Precise control with intelligent motor control devices

Wide array of device level components
 More information – where you need it when you need it

Enhances your plant asset management system
 Improved uptime
Warnings in advance of failure
 Troubleshooting tools and information at your fingertips

Lowest Total Cost of Ownership
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Agenda
IntelliCENTER Technology
What is it and how does it improve the design & operation of an MCC?
Embedded Systems & Intelligent Motor Control
Software & Controller Integration
IntelliCENTER MCC Return on Investment Case Study
How does it lower the installation & operating costs of an MCC?
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Embedded Systems – Integration via EtherNet/IP
 A single network for all Automation and Process control equipment
 Seamlessly linked to the front office for increased access to information
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Embedded Systems – EtherNet/IP Design
 Design consistent with DeviceNet IntelliCENTER

Cables are behind the vertical wireway

Does not take up any additional space

24V power supply required
 Easy to install in the field

All nodes preconfigured with the IntelliCENTER database pre-built at the factory
 Robust, noise immune network solution
EtherNet/IP Structure
EtherNet/IP Units
 600V UL-listed Ethernet cable
(Rockwell Automation exclusive)
 PowerFlex® Drives
 SMC™ Flex Soft Starters
 E1 Plus™ Overload Relays for Starters
 Stratix 5700™ Industrial Switch
 E300™ Overload Relays for Starters
 Point I/O™
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Embedded Systems – EtherNet/IP Design
The EtherNet/IP network in CENTERLINE MCCs has been tested to the
most rigorous standards for electrical noise immunity.
Lightning Strike
Industrial Noise
 +/- 2KV, 40A surge repeatedly
applied to the network cable
 IEC 61000-4-5
 +/- 1KV high voltage burst applied
to the network cable
 IEC 61000-4-4
No Communication Failures!
No Dropped Packets!
Less Down Time!
Radio Frequency Interference
 150kHz … 80MHz interference
applied to the network cable
 IEC 61000-4-6
PUBLIC INFORMATION
Static Discharge
 +/- 8KV ESD event at 12 locations
on the MCC and network cable
 IEC 61000-4-2
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
CENTERLINE 2100 MCC
IntelliCENTER EtherNet/IP Layout
Power Supply
SMC Flex
193-ETN
(E1 Plus)
PowerFlex 755
2113*
(E300)
PUBLIC INFORMATION
EtherNet/IP Connections
24V DC Connections
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
CENTERLINE 2500 MCC
IntelliCENTER EtherNet/IP Layout
Power Supply
2113*
(E300)
PowerFlex 755
193-ETN
(E1 Plus)
PUBLIC INFORMATION
SMC Flex
EtherNet/IP Connections
24V DC Connections
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER EtherNet/IP Topology #1
MCC Sections Connected via Switch-Level Linear Topology
Enterprise-wide
Business Systems
Levels 4 & 5 – Data Center
Enterprise Zone
Level 3.5 - IDMZ
Cell /Area Zone # 1
Machine
Plant-wide
Site-wide
Level 3 - Site Operations
Industrial Zone
FactoryTalk Application Servers & Services Platform
Network Services – e.g. DNS, AD, DHCP, AAA
Remote Access Server (RAS)
Call Manager
Levels 0-2
Storage Array
Cell/Area Zones
Physical or Virtualized Servers
•
•
•
•
•
Operation Systems
Cell/Area Zone #3
Electrical Distribution System
Power Control Room MCC Sections
Section 1
Section 2
Section N
Cell/Area Zone #2
Industrial Automation & Control System
Motor
Control
Center
CIP/MMS
Gateway
Security
Appliance
PUBLIC INFORMATION
IEC 61850
MMS
Reporting
Switchgear
Substation
E-House
Co-Gen
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER EtherNet/IP Topology #2
MCC Sections Connected via Switch-Level Ring Topology
Enterprise-wide
Business Systems
Levels 4 & 5 – Data Center
Enterprise Zone
Level 3.5 - IDMZ
Cell /Area Zone # 1
Machine
Plant-wide
Site-wide
Level 3 - Site Operations
Industrial Zone
FactoryTalk Application Servers & Services Platform
Network Services – e.g. DNS, AD, DHCP, AAA
Remote Access Server (RAS)
Call Manager
Levels 0-2
Storage Array
Cell/Area Zones
Physical or Virtualized Servers
•
•
•
•
•
Operation Systems
Cell/Area Zone #3
Electrical Distribution System
Power Control Room MCC Sections
Section 1
Section 2
Section N
Cell/Area Zone #2
Industrial Automation & Control System
Motor
Control
Center
CIP/MMS
Gateway
Security
Appliance
PUBLIC INFORMATION
IEC 61850
MMS
Reporting
Switchgear
Substation
E-House
Co-Gen
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Agenda
IntelliCENTER Technology
What is it and how does it improve the design & operation of an MCC?
Embedded Systems & Intelligent Motor Control
Software & Controller Integration
IntelliCENTER MCC Return on Investment Case Study
How does it lower the installation & operating costs of an MCC?
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
IntelliCENTER Software – Overview
System Level Dashboard
 Virtual view of the MCC
Component Configuration
 Parameter Editor
 Simple dashboard presentation
 Device monitoring and
configuration
 Customer configurable
 Remote diagnostic support
 Exclusive functionality for
MCCs
 Support for all IMC devices
in the MCC
 Trending and event logging
HMI support
ActiveX and IMC faceplates provided
Enables simple integration with On-Machine HMIs
Asset Management
Key customer documentation
 User Manuals
 Customized wire
diagrams
 Spare Parts lists
IntelliCENTER Software allows users to efficiently Operate & Maintain their MCC
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
IntelliCENTER Software – Energy
IntelliCENTER Energy is a premier software package with all the features of
IntelliCENTER PLUS additional Energy Management benefits powered by
FactoryTalk® EnergyMetrix™:
 Real-time energy consumption and historical
trending down to the device level, all across the
network!
 Ability to monitor and manage energy usage for
substantial cost savings
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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
IntelliCENTER Software – Integration Assistant
 Provides valuable integration features
1. Automatically build the I/O tree for all Intelligent Motor Control devices in the MCC
2. Auto-generate the device tags using Device AOPs
 Full integration between power and control for Rockwell Automation products
 Exclusive integration capabilities
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
IntelliCENTER Software – Integration Assistant
Simple integration of devices into Studio 5000
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Studio 5000 Premier Integration
 Premier Integration via
Device Add-On Profiles
(AOPs)
 Device parameters
automatically mapped to
controller tags in Studio 5000
 Configure and program all
intelligent motor control
devices in Studio 5000
 Configuration stored in the
controller to simplify device
replacement (in ACD file)
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Technology
Studio 5000 Automatic Device Configuration (ADC)
3:00 AM
Stratix
5700
EtherNet/IP
Configuration
Flash
IP Address
Saves the End-User time / money by reducing down-time
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
19
Agenda
IntelliCENTER Technology
What is it and how does it improve the design & operation of an MCC?
Embedded Systems & Intelligent Motor Control
Software & Controller Integration
IntelliCENTER MCC Return on Investment Case Study
How does it lower the installation & operating costs of an MCC?
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Motor Control Center
Value Statement
 A Rockwell Automation IntelliCENTER Motor Control Center can help
you reduce your installation and 1st year operating cost by ~20%
 Four key areas of value:
 Installation time
 Integration
 Energy use
 Downtime avoidance
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER Motor Control Center
Return on Investment Case Study
 The following whiteboard video shows
how an IntelliCENTER MCC helps you
lower your total cost of ownership
CENTERLINE® MCC Return on Investment Calculator
Prepared for:
Customer Name Here
Assumptions
MCC Pricing
Unintelligent MCC Purchase Price
IntelliCENTER® MCC Purchase Price
$50,000.00
$56,000.00
Cost Assumptions
Control Wire ($/m)
Conduit ($/m)
Logic I/O Cards ($/point)
EtherNET/IP Card
Energy ($/kWh)
Downtime ($/hr)
Electrician Hourly Rate ($/hr)
Engineering Hourly Rate ($/hr)
Engineering Time Per I/O Point (hr)
Electrician Time Per I/O Point (hr)
$0.65
$46.00
$20.34
$1,410.00
$0.09
$2,000.00
$26.00
$45.00
0.40
0.50
Savings Assumptions
Energy (%)
Downtime Avoidance (hr)
Non-Intelligent MCC Characteristics
Distance from MCC to controller (m)
Number of I/O points
MCC Amperage Rating (A)
Voltage Rating (V)
Loading %
Shift Length (hr)
Number of Shifts/Day
Operational Days Per Year
2.00%
1.00
20.00
100.00
1600.00
480.00
80.00%
8
2
280
Prepared By:
Rockwell Representative Name Here
Calculated Savings
Labor Costs
Engineering ($)
Engineering (hr)
Electrician ($)
Electrician (hr)
Total ($)
Total (hr)
Relative %
Date
1/12/2014
$1,800.00
40.00
$1,300.00
50.00
$3,100.00
90.00
5.54%
Material Costs
Wire
Conduit
Logic I/O Cards
Correction (EtherNET card)
Total ($)
Relative %
$1,300.00
$920.00
$2,034.38
-$1,410.00
$2,844.38
5.08%
Energy
Total Energy Draw (kW)
Energy Cost Per Hour
Total Energy Cost Per Year
Potential Energy Savings
Relative %
614.4
$55.30
$247,726.08
$4,954.52
8.85%
Downtime
Potential Downtime Savings
Relative %
Totals
First Year Savings ($)
Relative %
$2,000.00
3.57%
$12,899
23%
*These calculations are meant to provide an estimate of POTENTIAL savings only. They are not to be taken as a guarantee.
Ask your Rockwell Automation Sales Engineer to help you
calculate the savings an IntelliCENTER Motor Control Center
would provide your application!
PUBLIC INFORMATION
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.
Questions?
Thank you for your time!
Rev 5058-CO900E
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.