1. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Considerations for Designing an Intelligent Motor Control Center

2. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Embedded Systems and Intelligent Motor Control IntelliCENTER Technology What is it and how does it improve the design and operation of an MCC? Software and Controller Integration IntelliCENTER MCC Return on Investment Case Study How does it lower the installation and operating costs of an MCC? 3. Copyright 2014 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 and strengthen enterprise solutions 4. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Value of IntelliCENTER Technology 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 5. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Embedded Systems and Intelligent Motor Control IntelliCENTER Technology What is it and how does it improve the design and operation of an MCC? Software and Controller Integration IntelliCENTER MCC Return on Investment Case Study How does it lower the installation and operating costs of an MCC? 6. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. EtherNet/IP for Seamless Integration A single network for all Automation and Process control equipment Seamlessly linked to the front office for increased access to information 7. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 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 PowerFlex Drives SMC Flex Soft Starters E1 Plus Overload Relays for Starters E3 Plus Overload Relays for Starters Point I/O EtherNet/IP Units 600V UL-listed Ethernet cable (Rockwell Automation exclusive) Stratix 5700 Industrial Switch EtherNet/IP Structure 8. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. +/- 2KV, 40A surge repeatedly applied to the network cable IEC 61000-4-5 Lightning Strike +/- 1KV high voltage burst applied to the network cable IEC 61000-4-4 Industrial Noise +/- 8KV ESD event at 12 locations on the MCC and network cable IEC 61000-4-2 Static Discharge 150kHz 80MHz interference applied to the network cable IEC 61000-4-6 No communication failures! No dropped packets! Less down time! The EtherNet/IP network in CENTERLINE MCCs has been tested to the most rigorous standards for electrical noise immunity. EtherNet/IP Design Radio Frequency Interference 9. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Power Supply 2100-ENET (E3 Plus) SMC Flex 193-ETN (E1 Plus) PowerFlex 755 EtherNet/IP Connections 24V DC Connections CENTERLINE 2100 MCC IntelliCENTER EtherNet/IP Layout 10. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Power Supply SMC Flex PowerFlex 7552100-ENET (E3 Plus) 193-ETN (E1 Plus) EtherNet/IP Connections 24V DC Connections CENTERLINE 2500 MCC IntelliCENTER EtherNet/IP Layout 11. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Cell/ Area Zone # 2 Industrial Automation & Control System Cell/Area Zone # 3 Electrical Distribution System Physical or Virtualized Servers FactoryTalk Application Servers & Services Platform Network Services e.g. DNS, AD, DHCP, AAA Remote Access Server (RAS) Call Manager Storage Array Cell/ Area Zone # 1 Machine Enterprise-wide Business Systems Levels 4 and 5 Data Center Enterprise Zone Level 3 - Site Operations Industrial Zone Levels 0-2 Cell/Area Zones Level 3.5 - IDMZ Section 1 Section 2 Motor Control Center Section N Power Control Room MCC Sections Security Appliance IEC 61850 MMS Reporting CIP/MMS Gateway Switchgear Substation E-House Co-Gen Plant-wide Site-wide Operation Systems IntelliCENTER EtherNet/IP Topology #1 MCC Sections Connected via Switch-Level Linear Topology 12. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Cell/Area Zone # 3 Electrical Distribution System Power Control Room MCC Sections Section 1 Section 2 Motor Control Center Section N Physical or Virtualized Servers FactoryTalk Application Servers & Services Platform Network Services e.g. DNS, AD, DHCP, AAA Remote Access Server (RAS) Call Manager Storage Array Cell/ Area Zone # 1 Machine Enterprise-wide Business Systems Levels 4 and 5 Data Center Enterprise Zone Level 3 - Site Operations Industrial Zone Levels 0-2 Cell/Area Zones Level 3.5 - IDMZ Cell/ Area Zone # 2 Industrial Automation & Control System Security Appliance IEC 61850 MMS Reporting CIP/MMS Gateway Switchgear Substation E-House Co-Gen Plant-wide Site-wide Operation Systems IntelliCENTER EtherNet/IP Topology #2 MCC Sections Connected via Switch-Level Ring Topology 13. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Embedded Systems and Intelligent Motor Control IntelliCENTER Technology What is it and how does it improve the design and operation of an MCC? Software and Controller Integration IntelliCENTER MCC Return on Investment Case Study How does it lower the installation and operating costs of an MCC? 14. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. IntelliCENTER Software HMI Support System Level Dashboard Component Configuration Asset Management Virtual view of the MCC Simple dashboard presentation Customer configurable Exclusive functionality for MCCs Parameter editor Device monitoring and configuration Remote diagnostic support Support for all IMC devices in the MCC Trending and event logging Key customer documentation: User manuals Customized wire diagrams Spare parts lists ActiveX and IMC faceplates provided Enables simple integration with On-Machine HMIs 15. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. IntelliCENTER 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 16. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. IntelliCENTER 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 Add-On Profiles (AOPs) Full integration between power and control for Rockwell Automation products Exclusive integration capabilities 17. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. IntelliCENTER Integration Assistant Rockwell Software Studio 5000 Simple integration of devices into Studio 5000 18. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Software 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) 19. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Agenda Embedded Systems and Intelligent Motor Control IntelliCENTER Technology What is it and how does it improve the design and operation of an MCC? Software and Controller Integration IntelliCENTER MCC Return on Investment Case Study How does it lower the installation and operating costs of an MCC? 20. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. IntelliCENTER Motor Control Center Value Statement A Rockwell Automation IntelliCENTER Motor Control Center can help to reduce installation and first year operating costs by up to 20% Four key areas of value: Installation time Integration Energy use Downtime avoidance 21. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Unintelligent MCC Example Example unintelligent MCC, price is $50,000 4 columns 5 units/columns 5 I/O points per unit 5 drives 15 starters ACME UNINTELLIGENT MCC Factory Floor PLC Control Room For this example MCC, we will estimate the IntelliCENTER equipped price to be $56,000 22. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Do-It-Yourself Integration Hardware Conduit installation Wire cutting, stripping, preparation, and pulling Labeling, updating drawings Testing, possible rework Programming I/O mapping Tag creation Device configuration HMI integration Testing, troubleshooting 23. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Example - Materials Material costs for hard-wiring: Wire:$0.65 per meter / wire Conduit: $46 per meter Logic I/O Cards: $20.34 on average per point Calculations: 20 meters * $46/meter = $920 in conduit 20 meters * 100 wires * $0.65/meter = $1,300 in wire 100 points * $20.34/point = $2,034 in I/O cards $4,254 for cost of materials 24. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Example Labor Labor costs for hard-wiring: Including wiring, terminating, labeling, updating drawings, and testing we estimate 30 mins per I/O point 50 hrs for 100 I/O points Assuming low-cost resources at $25/hr, $1,250 in electrician labor Labor costs for Integration/Testing: Including programming, testing, and troubleshooting 5 days = 40hrs Assuming $44/hr, $1,760 in engineering labor $3,010 in labor costs and 11 persons / days of work 25. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Total Costs Before Startup Total material costs: $4,254 Total Labor costs: $3,010 Total person-days of startup time: Approximately 11 days $7,264 estimated in total costs prior to startup Time is money. Are your projects ever behind? 26. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Cost Correction With the IntelliCENTER package, you will need an EtherNet/IP card for your controller Since we took the cost of the discrete I/O cards into account earlier, we will subtract the cost of the EtherNet/IP card to give us a real cost comparison: $7,264 $1,410 = $5,854 $5,854 in corrected costs prior to startup 27. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Initial Savings $5,854 is roughly equivalent to 10% of the price of the unintelligent MCC Since the IntelliCENTER option typically only accounts for an estimated 10% of the unintelligent MCC cost (or 12% in our example), we have illustrated savings that account for almost its entire cost The cost savings when compared to the cost of the IntelliCENTER MCC is roughly 9% in our example In our example, the IntelliCENTER option almost pays for itself before you even turn it on for the first time! 28. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Energy A 1600A, 480V MCC will draw 614.4kW running at 80% efficiency At $0.07/kWh, this correlates to $43.00/hr in energy Running 2 shifts a day (16 hours), 280 days a year, this means $192,640 in energy each year is passing through your MCC, almost 4 times the original purchase price! An MCC will distribute multiples of its purchase price in energy each year! 29. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Energy Savings Through energy-monitoring enhancements in IntelliCENTER, we can provide you with pre-configured access to the following information: Real-time energy consumption information for the MCC down to the unit level including historical trending - Most manufacturers monitor at the line level, rarely do they monitor at the load level (more granular insight) to make energy decisions Power-quality analysis - Power factor penalties can add 10-30% to your electric bill Alarms for when energy consumption at the MCC or a particular unit is beyond a set level - Peak demand charges can be 20% or more of your electric bill! Using this information to make smart decisions about your process, you can potentially save on your energy bill. Imagine being able to save even just 2%... that correlates to a savings of $3,852 each year which is almost 10% of the purchase price of the MCC in our example! The savings that can be gained through energy monitoring and smart decisions can be huge! 30. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Maintenance Costs Motor Example Motors seldom fail instantly. Through intelligent monitoring of drive parameters, you can give your maintenance personnel insight that can help them catch motor problems before they become expensive motor failures. Device failures can be prevented Failure distribution statistics Source: IEEE Petro- Chemical Paper PCIC-94-01 75% of motor failures can be prevented 31. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Maintenance Costs Motor Exam Can you afford to have your line down for even one unexpected hour? Knowledge is power, take advantage of the insight gained through intelligent monitoring of your MCC system to reduce your downtime Saving even just 15 minutes of downtime at a very conservative cost of $2,000/hr each year is almost 4% of the initial purchase price of our example MCC! If you can eliminate even just one downtime event, youve paid for IntelliCENTER and then some! Average downtime costs per hour by industry Electronics $500,000 Paper $36,000 Rubber $25,000 Plastic $12,000 Automotive $1.6M Oil& Gas $3M Pharma $1.1M Food & Bev $8,000 Chemicals $700,000 Metals $600,000 32. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Summing it all up This example has illustrated the following cost savings over the course of one year $5,854 in material and labor costs $3,852 in potential energy savings $2,000 in potential downtime savings Approximately 21% in cost savings in the first year using conservative numbers Over a typical 20-year lifecycle the savings can add up to $50k in todays dollars for our example An IntelliCENTER MCC can help you achieve a cost savings of at least 20% on integration and first year operation! 33. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. Calculate your Potential Savings 34. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think! On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 34 Please take a couple minutes to complete a quick session survey to tell us how were doing. 2 3 4 1 Thank you!! 35. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Questions? Thank you for your time!