Intelligent Motor

Control Centers The Present

and the Future
Dave Blair
Commercial Marketing Manager
Rockwell Automation MCC Business

Greg Witte
AGG/Cement & Mining Bus Dev Mgr
Rockwell Automation Sales Group

Motor Control Center Overview

MCC is basically just
familiar motor control
components in a common
enclosure

Combination
Starters
Circuit
Breakers

Intelligent Motor Control Centers - 2

The MCC Difference: Ability to Plug In

Plug in an
Electric Device

Plug in a Combination Starter

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Definitions

Section
-provides grid
of power
-integral
wireways

Unit
-plugs into section

Intelligent Motor Control Centers - 4

1990s: Clear Trend Toward

More Intelligence in MCC
35% of sections include
intelligent products:

AC drives
Solid-state controllers
PLC I/O chassis
Power monitoring devices
Electronic overload relays

Drivers
More devices designed to fit plugin units
Fault containment
Servicing of devices with adjacent
equipment energized
Wiring and installation time
Intelligent Motor Control Centers - 5

Integration Accomplished via Hardwiring

Devices hardwired to I/O Chassis

On-Off control and monitoring
Contactor status
Disconnect status
Overload status

Transducers sometimes used for

process monitoring

I/O
Chassis

To
Processor

Roundtables held in 1998 to discuss opportunities for better

utilizing current technology and integrating new technology
Intelligent Motor Control Centers - 6

User Roundtables Provided Great Insight

1. Users focusing more on device intelligence and system
integration than traditional MCC features
2. Users approaching device-level communication networks
with caution
3. Users demanding useful information
Improved diagnostics and predictive failure information

intelligence in all end devices, not just critical areas

networked access to device information
real-time device monitoring and trending
process or component history

4. Users demanding Plug & Play solutions

Pre-tested, pre-configured systems for reduced installation time & start-up
User-friendly PC interface

Intelligent Motor Control Centers - 7

Consider the Following Scenario

What tripped?
Why did it trip?

Was it preventable?

How do we fix it?

Is anything else going to trip
how soon?
Enough with technology.
Provide answers to these simple questions!
Intelligent Motor Control Centers - 8

The Future of MCCs

The Intelligent MCC

Concept
Traditional interwiring replaced
by single open device-level
network cable
Network-ready device in every
MCC unit
Transportable MCC software for
monitoring and documentation
System pre-tested and preconfigured before shipment

Intelligent Motor Control Centers - 9

Network Cabling Alternatives

Obvious Cabling Approach

Route Cabling Through
Wireways
Trunk line in horizontal wireway
Drop line in vertical wireways
Device connected via daisy chain

Typical Smart MCC Lineup

Control-level Network
Device-level Network Trunk Line
Device-level Network Drop Line
Intelligent Motor Control Centers - 10

Network Cabling Alternatives

Optimized Cabling Approach
Network cabling behind barriers
Prevents damage which may occur
during installation

8A, Class 1 cabling

Eliminates need for >1 power supply
in most MCC line-ups
Eliminates need for separation from
power cables

Intelligent MCC Line-up

Built-in Device-level Network

Plug-in Device-level cable
Control-level Network
Intelligent Motor Control Centers - 11

Network Cabling Alternatives

Optimized Cabling Approach
Device-level network ports
in each vertical wireway
Simplified installation,
relocation, and adding of units
Superior to daisy-chain, where
downstream equipment may
unintentionally be shut-down

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Network-ready Devices
Interface Module for
Non-intelligent units
Network capability required in all
units, even non-intelligent units
Traditional motor starter
Feeder and main disconnects

Solution: Low-cost, mini

I/O Chassis in each unit
4 inputs and 2 outputs
monitoring of contactor, hand-off-auto,
overload relay, and disconnect
direct control of contactor coil

Devicelevel
Network
DI
DO

Starter Auxiliary Contact

Hand -Off-Auto (HOA)
Overload Auxiliary Contact
Disconnect Auxiliary Contact

Typical FVNR Wiring

Intelligent Motor Control Centers - 13

Network-ready Devices
Electronic Overload Relay
at Core of Intelligent MCC
Protection that extends beyond
OL protection

Thermal Overload
Phase Loss
Stall (high overload during start)
Jam (high overload during run)
Underload
Current Imbalance
Zero sequence ground fault,
sensitive to 1A

Input points

Programmable
protective functions

alarm level
trip level
time delay
inhibit window)

Information:

Time-to-trip
Time-to-reset
Percent thermal capacity
Cause of last 5 trips and
warnings
Intelligent Motor Control Centers - 14

Electronic OL Relay Capabilities Illustration

Solid-state
DeviceNet
Overload Comm Module

+
I/O Aux.
Module

+
Ground Fault

+
Jam / UL
Relay

Thermistor
Relay
Intelligent Motor Control Centers - 15

Transportable MCC Software

The ultimate window into MCCs

MCC monitoring in Windows environment

Pre-configured screens display real-time information
Complete system documentation
Software optimized to ensure performance
Polling algorithm segregates monitoring and control, so
monitoring scans do not affect control scans

Intelligent Motor Control Centers - 16

Transportable MCC Software

Elevation View
Unit View
User Manuals
AutoCAD Drawings

Additional Screens

Spare parts
Event logging
Spreadsheet view

Intelligent Motor Control Centers - 17

Transportable MCC Software

Software can reside
anywhere in users
facility
Control room
Engineers desk
Laptop used by
maintenance
personnel

Flexibility made
possible by
communication driver

Programmable
Device Support
PC

MCC Software

MCC Software

Desktop PC

Gateway or Linking Device

MCC Software

Maintenance PC

Multiple MCC Line-ups

Intelligent Motor Control Centers - 18

The Future of MCCs

The Intelligent MCC

Software provides ultimate window into MCC

Real-time monitoring
Access from anywhere in the facility
Complete documentation and MCC history

Device-level products capture new information

Allows predictive maintenance, process monitoring, and
advanced diagnostics

Built-in network simplifies MCC design and

installation
Ease of moving and adding units
Prevents accidental damage to network cables

Plug & Play system

Pre-tested and pre-configured
No set-up, no programming, no expert required

Intelligent Motor Control Centers - 19

profit
low!

profit
low!

profit
low!

Ethernet

Conveyor / Zone Controller

ControlLogix/ProcessLogix
PV 1000C

Hazardous Area
ControlNet

Flex EX I/O

CNET
Fieldbus

ControlLogix
CNET
DNET

DeviceNet
Flex I/O

509 -BOD

EZ-Link

EZ-Link

Controlled Start
Transmission

24vdc

PV 600C

1305/1336+
Drive

Open Network for Mine Site Monitoring and Control

Intelligent Motor Control Centers - 20

Typical Devices on DeviceNet

Sensors, actuators & switches

Simple Human-Machine Interfaces
Operator Interfaces
Push buttons
Micro Drives
DeviceNet
Robots
Software
Pneumatic Valves
Bridges/Gateways etc.

ALLEN-BRADLEY

PanelView 550

<
F1

F2

F3

F4

F5

F7

F8

F9

F1
0

^
<

F6

<-----------------'

>
v

Device Network Positioning

Process
Complex devices
Discrete
Simple devices

Device Size
Device Cost
Installer
Information

100s in.3
$1,000-$10,000
Technician
Multi-variable

10s in.3
$100-$1,000
Electrician
On/Off, status

While
Whileoverlap
overlapexists,
exists,polarized
polarizedneeds
needsdemand
demand
two
twophysical
physicalnetworks
networks

Network Specifications
Physical Media

Network Power

Maximum Devices

24vDC power to devices

Thick & Flat trunk rated to 8 amps 64 Nodes per Network
Thin wire rated at 3 amps

ALLEN-BRADLEY

(Shielded Twisted Pair)

Communications and Power
Thick - Trunk or drop
Thin - Trunk or Drop
Flat - Trunk only

Trunk line Distance

and Baud rate
100m Max. with Thin cable
500m @ 125Kbaud (thick)
250m @ 250Kbaud (thick)
100m @ 500Kbaud (thick)
(4Km with Repeaters)

PanelView 550

<
F1

F2

F3

F4

F5

F6

F7

F8

F9

F1
0

<-----------------'

^
<

>
v

Device Connections
T-Taps
Zero-drop

Cumulative
Drop-line Budget

Terminating Resistors
120 Resistors at both
network trunkline ends

Messaging Services
Producer/Consumer
High-speed I/O
Programming
Configuration
Diagnostics

Drop-line wiring

156m @ 125Kbaud
78m @ 250Kbaud
39m @ 500Kbaud

Single drop
(Maximum of 6m each)
Daisy-chaining off drop
Branching off drop
Intelligent Motor Control Centers - 23

Open DeviceNet Vendor

Association (ODVA)
Ownership of DeviceNet technology
Specifications
Electronic Data Sheets (EDS)
Trademark

Over 360 members worldwide

ABB, Allen-Bradley, ASCO/Joucomatic, Banner, Beldon, CutlerHammer, Festo, Hitachi, Intellution, Mitsubishi, Modicon, Nematron,
Omron, Parker Hannifin, Pepperl+Fuchs, Reliance, Square D, SMC,
Toshiba, Turck, Wonderware, etc.

Over 40 SI/OEM members

Alvey, Jervis B. Webb, KR Automation, Rapistan Demag, ...

Internet Home Page (http://www.odva.org)

On-line Product Catalog
Newsletters/Current Events
Member companies + contact names
Specifications order form

Intelligent Motor Control Centers - 24

CAN is an excellent foundation for a simple device

network
(Controller Area Network)
CAN is open technology supporting multiple
applications
Chips available today from Intel, Motorola,
Philips/Signetics, NEC, Hitachi, Siemens
Volumes from multiple industry usage insures
downward price pressure -over 120 million chips in 2000
Original use in automobile environment
- an excellent proxy for industrial applications
- temperature extremes, high noise environment

Intelligent Motor Control Centers - 25

What is the basis of DeviceNet??

In terms of network bandwidth

efficiency and overall system
performance, DeviceNet have
implemented a paradigm that is
ahead of traditional sourcedestination networks. Its called
Producer - Consumer.

Intelligent Motor Control Centers - 26

Source/Destination Example
One person (source) tells each person
(destinations) in the room, one at a time,
the current time of day (data)
People may choose to ignore, but time and
effort is wasted
Time will pass as the source
communicates to each
destination, one by one
Delivery time changes with the
number of people in the room
Intelligent Motor Control Centers - 27

Producer/Consumer Example
One person states (produces) the current
time of day (data) once to one or more
people (consumers)
All people hear the data simultaneously
Some people may choose to listen to
(consume) the data (acknowledge
by nodding, adjust their watch, etc.)
Others may choose to ignore
(not consume) the data
Highly efficient
(delivery time consistent if
more people enter or people leave the room)
Intelligent Motor Control Centers - 28

DeviceNet Cable Highlights

Red
White
Bare
Blue
Black

+24VDC ( V+ )
CAN-H
Shield
CAN-L
+0VDC ( V- )

5 Conductors
1 pair for 24 Volts DC power
1 pair for CAN communication
1 Shield
Intelligent Motor Control Centers - 29

Node Commissioning of Devices

Every DeviceNet device needs at a minimum a unique
node address (0-63) and appropriate data rate (125kb,
250kb, or 500kb) set prior to gaining access to the
network.
NOTE: devices default to address #63, data rate
125 kbps

Intelligent Motor Control Centers - 30

Replacing Devices
Set node address, data rate (or
Autobaud)
Configure device parameters
Connect device to system
Slave devices must pass electronic key
device type
manufacturer
part number

NEW! Auto Device-Replace ( ADR )

Intelligent Motor Control Centers - 31

Auto Device Replace ( ADR )

ADR consists of two parts which are Node Recovery and Configuration
Recovery. Node Recovery cause the node number of the replacement
device to be automatically changed to the node number of the original
device.

Configuration Recovery will cause the replacement devices configuration to

be made identical to the original device.
ALLEN-BRADLEY

Original Device
#55

Replacement Device
#63

Intelligent Motor Control Centers - 32

Configure and Monitor Devices Online

Using an Electronic

Data Sheet (EDS) for any device, from any vendor,

configure and monitor

devices Online. The EDS file format is a standard and is defined by ODVA in the DeviceNet specification.

Intelligent Motor Control Centers - 33

EZLINK Smart Bearing

Each EZLINK interface acts like a node on

the network and give back diagnostic
information about the bearing status back to
the network master. ( Speed, vibration and
temperature )
Dodge bearing also has available a PC based
monitoring software package that also
monitors the diagnostic information over
DeviceNet. The software then displays the
data in various forms such as meters, graphs
etc.

Intelligent Motor Control Centers - 34

Reliability Centered Maintenance

RCM Experience - 50 to 70 percent of Maintenance should
be done based on equipment condition!
Asset maintenance requirements

Reliability Centred Maintenance

Design Out

Run to Fail

Planned

Engineering

Breakdown

CMMS

Predictive
CM

Intelligent Motor Control Centers - 35