AutomationToday 2011 Aug-Oct

AutomationAutomationAugust - October 2011

TODAY ASIA PACIFICIndia

that Complements the Automation Architecture

Design a

ComponentInfrastructure

See page 8

InsideSmall-Size PLCs DeliverJust the RightControl Capabilities

High-Performance Drives Provide Flexibility in Motor Control

Toolkit Helps DesignersOptimise Machine Operations

The Power of Partnering

How Control and SafetySystems Coexist

Scott Summerville, PresidentRockwell Automation Control Systems, Asia Pacific Region

AUTOMATION TODAY ASIA PACIFIC August - October 2011 1

EDITORIAL CONTENTSEDITORIAL

Automation Today is published byROCKWELL AUTOMATION INTERNATIONAL LLC

Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong

Editor: Ricky AuYeung – [email protected]

ROCKWELL AUTOMATION INDIA (PVT.) LTD.

Contact: Debashish [email protected]

Copyright© 2011 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner. Allen-Bradley, Automation Fair, CENTERLINE,

ReducingTime to Market

Machine builders, especiallythose who develop low-cost, stand-alone equipment, spend

considerable time on control system design. They are focused on improving machine performance for their end users. Any time that these original equipment manufacturers (OEMs) can save in the process translates into a competitive advantage – reducing time to market.

To help speed control system design, Rockwell Automation® offers a range of solutions that make it faster and easier to implement common control-design tasks. These solutions enable machine builders to put together an integrated infrastructure to optimize their designs.

At the heart of this infrastructure are core components including Rockwell Automation nano and micro controllers, PowerFlex® 4 drives and PanelView™ Component human-machine interfaces (HMIs). Application development tools known as Connected Components Building Blocks (CCBBs) complement the core and provide pre-developed aids – such as HMI screens, panel layouts, wiring diagrams and application code – that help save valuable configuration time and minimize preparation work. To these core components, machine builders can add starters, motors, push buttons, sensors, safety devices and power supplies to complete their designs.

Rockwell Automation continuously works to enhance their offerings for OEMs. For example, in this issue of AutomationToday Asia Pacific, you can learn about our new Micro800™

family of controllers. These small-size programmable logic controllers (PLCs) deliver just the right control capabilities for machine builders.

Our recently introduced PanelView Plus 6 HMIs feature more memory with faster refresh rates, more on-device storage and an increase in processing speed from 650 MHz to 1 GHz. We have also added new application tools to our CCBB toolset, including those to help speed development of simple machine safety, energy management and motion control.

Beyond low-end OEM solutions, you can also read how our PowerFlex 753 and 755 drives integrate new concepts in functionality, size and protection. In addition, our Drives and Motion Accelerator Toolkit DVD is now available to help customers reduce the time and cost of developing new applications using PowerFlex AC drives and Kinetix®

servo drives.Rockwell Automation is always looking for ways to enhance

its offerings so that customers can improve their automation processes – and reduce time to market.

Bob Ruff

Bob Ruff, PresidentRockwell Automation, Asia Pacific Region

Features

8 Cover Story – Design a Component Infrastructure that Complements the Automation ArchitectureConnected Components Building Blocks application development tools help machine builders reduce time to market and enhance performance.

6 Feature Story – Small-Size PLCs Deliver Just the Right Control Capabilities

®

sets a new standard for convenience and ease of use.

10 Feature Story – High-Performance Drives Provide Flexibility in Motor Control

® 753 and 755 drives help

16 Feature Story – The Power of PartneringThe strength of a manufacturer’s partnering network brings business value and competitive advantage.

2 News & EventsRockwell Automation® developments from around the world.

4 Country NewsNews and events from around India.

12 Technology WatchRockwell Automation® tools and templates save machine builders time in developing control applications.

14 Safety

18 Product FocusRecent additions to the Rockwell Automation® product portfolio.

2 August - October 2011 AUTOMATION TODAY ASIA PACIFIC

NEWS & EVENTS

Avantha Power Selects Rockwell Automation for Plant-Wide Optimisation

Avantha Power, part of the Avantha Group, one of India’s leading business conglomerates, has selected Rockwell Automation® as its automation provider for the utility’s balance of plant (BOP) applications for the next three years.

The US$2.5 million estimated investment allows Avantha Power to adopt a common control platform for its entire BOP system, improving plant-wide optimisation as well as reducing life cycle costs.

The Rockwell Automation Integrated Architecture™ system will monitor and control up to nine BOP applications including coal and ash handling, mill reject, water treatment and fire protection systems at two coal-based thermal power projects; each consists of two 600 MW units being set up at Raigarh, Chhattisgarh, and Jabalpur, Madhya Pradesh, India. The Greenfield electric power plant projects will begin power production over an 18-month period, beginning in March 2012.

Rockwell Automation to Acquire Hiprom

Rockwell Automation® has entered into a definitive agreement to purchase Hiprom, a leading process control and automation systems integrator headquartered in Johannesburg, South Africa.

Hiprom customers include the top global mining firms with precious metal and coal operations in the Sub-Saharan region. The management team and its 100 employees will join the Rockwell Automation Systems & Solutions business unit. The acquisition will enable Rockwell Automation to better serve customer needs worldwide and expand its markets.

Remanufacturing Centres Offer Factory-Authorised Repair

Rockwell Automation® customers in China will now get significantly faster turn-around time on PanelView™ Plus remanufacturing services

because of recent investments in the Shanghai remanufacturing center.

In the past, PanelView Plus units were sent to the United States for remanufacturing, where the process took about 70 days. Transportation logistics to ship the units between the two countries was the main reason for long customer wait times and higher costs.

Now, units can be remanufactured onsite at the Shanghai facility in as little as 10 days. Nancy Li, business manager, CSM, explains that the project

strongly supports the Chinese market and that customers are more willing to cooperate with partners who make infrastructure commitments in China. Shanghai remanufactures about 150 PanelView Plus units each month.

Rockwell Automation has Remanufacturing and Exchange Services throughout Asia Pacific. Loh Kong Ngee, plant services operations manager, AP CSM, reports that a significant amount of high-turn rotable exchange stock has been added in the AP regions of China, Australia and India, including a new inventory hub in Singapore. Distributors and customers are encouraged to contact Rockwell Automation for rotable exchange stock and services.

A seven-step remanufacturing process restores failed units to “like new” or better condition, extending equipment life and enhancing performance. There are two levels of service. The first, Economy Services (Repair), involves sending the failed or malfunctioning product through the seven-step process and returning it via normal shipping, which can take up to six weeks. The second, Priority Services, enables customers to obtain next-day shipment from over 50,000 remanufactured Allen-Bradley® catalog items inventoried at the company’s global parts hubs.

By taking advantage of the service, customers can improve their overall equipment effectiveness and stabilise their maintenance budget. In addition, they can reduce unplanned downtime and frequency of repairs as well as receive repaired products faster.

NEWS & EVENTS

BRIEFS

Smart, Safe, Sustainable Manufacturing

The Rockwell Automation® 2010 Corporate Responsibility Report is now available online. Energy conservation and solid waste management continue to be the company’s top environmental priorities.

“Sustainability has evolved from a social

says Keith D. Nosbusch, chairman and CEO, Rockwell Automation. “Our report highlights our progress on those corporate responsibility issues most relevant to our customers, business and employees.

The report is available online at www.rockwel lautomat ion.com/about_us/responsibility.html.

Rockwell Automation Receives Magazine’s Top Honors

Rockwell Automation® secured seven first-place awards and four honorable mentions in the 24th annual Control Engineering’s 2011 Engineer’s Choice Awards.

With a focus on innovation, top finishes include:

More than 100 product nominations from

evaluation. Subscribers voted to identify the

based on technological advancement, service to the industry and market impact.

Rockwell Automation offers remanufacturing services

throughout Asia Pacific.

Optimal Machine Performance for Demanding Applications

From push buttons and terminal blocks to I/O systems and operator interface devices, Rockwell Automation®

offers a broad range of industrial products known as “EssentialComponents.” These products – including components for power, logic, connectivity, safety, sensors and switches – are the foundation of efficient automation. They enable users to select the right components they need for their applications at the right price.

Rockwell Automation has recently released their Essential Componentscatalog, which contains a wealth of information, divided by applications. Below is a sampling for your reference.

PowerPower devices are essential for power

switching – turning machinery on and off – and motor control – the ability to determine how and when motors operate. Various components protect motors and drives.

Control circuits and load protectionproducts protect electrical circuits from damage caused by overload.

electrical current, stopping it completely or diverting it.

to start and control electric motors.

critical elements of current, voltage and temperature to protect motors from overheating.

when to start, stop and how fast to operate. Correct sizing, installation and operation of a motor can reduce energy consumption by 20 percent.

Connection SystemsConnection systems provide plug-

and-play connections for plant-floor devices and safety applications.

electrical wires.

provide communication between an information processing system and the outside world. Systems receive input signals or data from devices and send output signals.

modules and cables that connect through pre-wired cable assemblies to I/O.

connectivity devices for industrial networks including Ethernet, ControlNet™ and DeviceNet™.

LogicLogic devices range from simple relays

to small programmable controllers. They utilise simple instructions to provide basic, automation control.

electronic circuits. A relay is an electrically operated switch; a timer controls the sequence of an event or process.

reduce temperature swings to guard against equipment overheating and reduce energy costs.

logic controllers (PLCs) provide basic control needs for simple machines.

SafetySafety components help increase

personnel safety while maintaining the functional operation of machinery.

control relays, safety I/O and safety PLCs perform the checking and monitoring of safety systems, allowing them to start or execute commands or stop altogether.

position of guards or gates.

people from injuries related to hazardous machine motion by detecting the presence of objects and people.

Operator InterfaceElectronic operator interfaces are

the windows into production, helping

operators see what’s going on and process that information.

™ Component human-machine interfaces provide low-cost visualisation products for small machine builders.

devices signal breakdowns and material shortages as well as alert operators of hazards.

Sensors and SwitchesSensors are input devices used

to detect a changing condition on the plant floor. Their output is the basis for monitoring and controlling manufacturing processes.

without making physical contact; they are not susceptible to mechanical damage or wear under normal circumstances.

mechanical devices. When an object comes into contact with an actuator, the limit switch operates the contacts to make or break electrical connections.

To learn more about these devices and to obtain your free copy of the Essential Components catalog – available in local language editions in China, India, Korea, Taiwan and Southeast Asia – contact the local Rockwell Automation office or local distributor.

ESSENTIAL COMPONENTSNEWS:

on the web

For more information on Essential Components, visit: www.rockwellautomation.com/components/index.html


COUNTRY NEWS


‘Rockwell Automation on the Move – Connect 11’ showcases the Power of Partnering

‘Rockwell Automation on the Move – Connect 11’ and RS TechED, a 4-day mega event was held in August 2011. Rockwell Automation India showcased the Power of Collaboration both internally and through RA’s PartnerNetwork that highlighted Smart, Safe and Sustainable manufacturing to the automation customer. This was the first such event held by an automation technology company in India to help customers and automation users with

Highlights include Smart,

Safe and Sustainable

technology solutions to help

Manufacturing and the Power

of Rockwell Automation’s

PartnerNetwork – a key

differentiator in the market

place

an unparalleled learning and non-stop networking opportunity. The success of this event largely hinged on a well orchestrated teamwork between RA India, US Global Marketing team, Europe and SE Asia.

The monsoon and the rain threats over South India didn’t dampen the enthusiasm of over 800 customers, Encompass partners and employees checking out the latest Rockwell Automation had to offer. A total of 6000

INDIA


AUTOMATION 2011, a just concluded trade show in Mumbai

showcased the ‘Power of Collaboration’. We supported the

two new joint ventures of Rexel, our Distributors in West Region with

an overall program management, booth design for this trade show.

We showcased our crowd pulling IA Wall and Component products.

The booth bagged two awards, one for the ‘Highest Footfall’ and

the Second Prize for the ‘Best Stall Design’ booth category. The

Distributor is overwhelmed by our support and also the number of

leads generated in this show.

square metres space occupied included Show Floor, Inaugural & Technology session area. Customers attended 40+ technical sessions, out of these 10 sessions had customer presenters. A new innovative addition to the session agenda was ‘SimPl-X’: the fun way of selling the Customer Support Maintenance Concept & Services to the customers. The Technical Experience session (Hands-on labs) was another area of interest amongst all the participants.

The highlight of the event was a Panel Discussion on ‘Technology Horizons’, led by Rajiv Makhni, a Technology Commentator and Analyst from a leading television channel. The

panelists were, Sujeet Chand, CTO Rockwell Automation, Douglas Bellin from Cisco Singapore, Murthy Uppuluri from Microsoft, and Vishwas Chitale, MD of Chitale Dairy, a Rockwell Automation Customer.

There were 27 Partner exhibitors, which included 11-Encompass and 12 RcSI’s. Microsoft & Cisco, Strategic Alliance Partners were the Gold sponsors of the event and Schaffner, an Encompass Partner was the Silver Sponsor. Aside of these Partner Booths, on showcase from RA were some of the newest and the most advanced power, control and information solutions technology.

The participants’ segmentation analytics indicated we had 175 Control Engineers, 110 Design Engineers, 310 Managers, 79 Directors, 20 Vice Presidents, 96 Distributors and 67 Exhibitors.

The tracks on Process, Power & Energy Management and the Customer Speakers’ sessions registered more than 75% attendance, with certain Process tracks receiving highest oversubscription by almost 170%.

Some testimonials received:Gary Pelham, Executive General Manager of Rexel Asia Pacific, one of our participating Distributors, wrote back saying, “Congratulations for the great success of the RAOTM Hyderabad event, I was extremely impressed with it and the professionalism you delivered. During the past 22 years I have attended so many of these large shows and truly it was above class with over 800 customers, distributors and partners in attendance. I am so pleased at the exposure this event has brought our customers and the sales teams . . . In addition we also discovered some good Encompass partner new product opportunities which we are working on to include in our business.”

D. Sarkar from Mott MacDonald, Consultants to the Process industries, wrote, “Thanks a lot for the kind hospitality during two days of RAOTM in Hyderabad early this week. It was a nice experience for me to be a part of the mega event. I congratulate you all for the grand success of the event. We will take our joint initiative forward based on various interactions and feedbacks received during the sessions.” AT

Automation 2011 Trade Show: Co-marketing with Distributor

GURGAONRockwell Automation India (P) Ltd.Regus Business Centre, Level 5,6 & 7 JMD Regent Square, Mehrauli Gurgaon Road Gurgaon, HaryanaPhone: 0124-4712000/01

LUDHIANARockwell Automation India (P) Ltd.H No. 52, Guru Nanak NagarNear Sector - 32A, Chandigarh RoadLudhianaMobile: 0 97800 09716

Rockwell Automation India (P) Ltd.No. 3, Pestige Obelisk, 7th Floor, Kasturba Road, Bangalore - 560001. Phone: 91-080-30706999


T he micro PLC and component market is estimated at about US$8 billion, approximately the

same as the large-size automation market. As the worldwide economy recovers, experts forecast continuing growth in this market.

Currently, the micro PLC segment of the automation market has no definitive leader, but a number of companies are competing for the top spot, including Rockwell Automation®. Recently, the company launched its Allen-Bradley MicroLogix™ 1400 in this space, targeting machine builders, or original equipment manufacturers (OEMs). In 2011, the company is stepping up its offerings with the introduction of the Allen-Bradley Micro800™ family of PLCs.

The new product line, previewed at the 2010 Automation Fair® in the United States, consists of a family

of PLCs that provide control capabilities geared for lower-end OEM applications. What’s more, it comes with the free standard edition of Connected Components Workbench™

software, which follows established IEC-61131 standards. In addition, the software supports not only the Micro800 controllers but also the Allen-Bradley PowerFlex® component-

class drives, PanelView™ Components human-machine interfaces (HMI) and motion products used in small machines.

The Price/Performance Combination

Kurt Rosenberg, Distributed I/O and Small Controllers business director, Rockwell Automation, explains that the Micro800 has been developed for companies that want their own customised features. It utilises plug-in modules to accomplish that.

“The new product line,” says Rosenberg, “is a plug-in system that allows I/O expansion without additional space and easy access through USB. It also supports various networks such as Modbus, ASCII, DeviceNet™ or EtherNet/IP™.” He adds that OEMs can plug in the modules that work for their application,

including motion, analogue/digital input and output, and discrete.

A key benefit is that the product line uses the Connected Components Workbench software. “This free, integrated engineering software designs, operates and controlsvarious components, including PLC, motion and HMI, in one platform,” notes Rosenberg.

The free software download helps minimise time to start machine development as well as time-consuming maintenance work. Because the software is easy to configure, it helps reduce time to commission machine controls. It provides a choice of programming languages with user-defined function block support (ladder diagram, function block diagram or structured text) to help optimise how users control their machines. In addition, robust debug features make machine commissioning easy to test and deploy.

There is also a Developer version of the software. It features run-time download, user-defined function blocks and controller simulation and is available for order through local Allen-Bradley distributors around the world.

The fact that the Micro800 provides serial modules and is a plug-in unit with free software differentiates it from competitors in terms of price and performance.

How is it different from the MicroLogix 1400, which was introduced two years ago? The MicroLogix 1400 is a block-type micro PLC with all features packaged together. The Micro800 is a flexible-type product line with plug-in modules. According to Rosenberg, it has been developed to fill the gap between the MicroLogix 1000 series and the CompactLogix™ series.

The new PLC line is launching

The next-generation micro PLC from Rockwell Automation sets a new standard for convenience and ease of use.

Small-Size PLCs Deliver Just the Right

ControlCapabilities

The fact that Micro800 provides serial modules and is a plug-in unit with free software differentiates it from competitors in terms of price and performance.


globally but is especially targeting users in Asia Pacific, including China, India and Australia. Research and development, production and manufacturing for the products take place in Singapore.

Nano- and Micro-Level Applications

The Micro810 is the entry-level product. The controller functions as a smart relay with high current relay outputs but with the programming capabilities of a micro PLC.

Its 12-pt form factor provides the following:

for external relays.

function as 4 0-10V analogue inputs.

programming port (adapter required).

monitoring/modifying application data (variables).

function blocks without programming (LCD required).

The Micro830 features flexible communications and I/O capabilities with up to six High-Speed Counter inputs. Different controller types share the same form factor and accessories. It also provides easy incorporation of as many as five plug-in modules on the 48pt models.

The Micro810 and Micro830 controllers are available immediately. Additional plug-in capabilities for

the controllers will be available later this year.

Plug-In ModulesOEMs can change the “personality”

of the base unit controller with plug-in modules. They extend the functionality of embedded I/O without increasing the footprint of the controller. They also can improve performance by adding more processing power or capabilities as well as communication functionality. In addition, Encompass™

Partner expertise can be added to enhance capabilities with tighter integration to the controller.

Several types of plug-ins are available:

Analogue input/output (2- or 4-channel, non-isolated). Up to 20 analogue inputs can be added.

Resistance temperature detector/thermocouple (2-channel, non-isolated). This makes temperature control possible when used with PID with auto-tuning. It transforms the low-cost Micro810 controller into a single loop temperature controller.

Trim potentiometer (6-channel, analogue input). This is a low-cost method of adding six analogue presets for speed, position and temperature control.

Serial port RS232/485 (isolated). It supports Modbus RTU and ASCII protocol.

Micro830 backup memory with real-time clock. One touch backs up data log and recipes. Removal and

insertion under power allows data to be retrieved without stopping the controller. Memory adds precision real-time clock function without needing to calibrate or update.

According to Rosenberg, Rockwell Automation has been making inroads into the micro PLC market: “We are confident that we can be a leader in the market if we promote the powerful benefits of the Micro800 product line and take advantage of the brand reputation we have gained in the high-end PLC market. Our OEM customers dislike anything complicated. They demand simple programs, simple composition and easy startups. The Micro800 line, with price and performance benefits, is designed to satisfy these needs.”

Craig Resnick, research director, ARC Advisory Group, notes, “Machine builders seek the best of all worlds: They want solutions that are priced to provide not only the essential capabilities that they require but also feature convenient, easy-to-use programming and configuration tools that minimise set-up and start-up times to maximise their profitability. The Allen-Bradley Micro800 PLCs and Connected Components Workbench software from Rockwell Automation appear to meet this machine builder demand for a customisable, cost-effective solution suited to stand-alone applications that require simple, time-efficient installation, configuration, programming and updating tools.” AT


The automation control system represents a major investment in a machine design. Beyond

selecting the right controller and human-machine interface (HMI), machine builders must also select components that will positively impact performance.

When machine builders view the entire automation bills of material as a comprehensive system and select components designed for seamless integration with the control and information architecture, they can improve machine performance – and uptime – for the end user. Rockwell Automation® uses a systematic approach to helping machine builders design this integrated infrastructure – known as Infrastructure for the Architecture – to optimise designs by:

accuracy of analogue control circuits.

of control panels.

within a panel.

outputs on a controller without purchasing an expansion module.

and other devices from damage due to short circuits, voltage transients and electrical disturbances.

and HMI devices operating in the event of a power failure and getting back to production much more quickly when power returns.

avoid errors in new installations or when retrofitting legacy systems.

Speeding Design TimeMachine builders spend a large

amount of time on control system design, which is why any savings can provide a critical competitive advantage. Application development tools make it faster and easier to implement common control-design tasks, allowing machine builders to concentrate on machine design.

The Connected Components Building Blocks (CCBBs) – built around a core of MicroLogix™ controllers, PowerFlex® drives and PanelView™

Component HMIs – offer machine builders a range of tools that can significantly reduce the design cycle. In using these tools – such as pre-developed HMI screens, panel layouts, wiring diagrams and application code – engineers also reduce the need to refer to multiple vendor manuals, helping save valuable configuration time and minimising tedious preparation work.

The CCBB ToolsetSince 2009, Rockwell Automation

has added more than 30 new building blocks to its offering. Among them are those designed to help speed development of simple machine safety, energy management and motion control applications.

For example, the E-Stop and Gate Switch String building block helps users configure a safety system for a simple machine. This solution employs an Allen-Bradley® Guardmaster®

MSR42 multi-function safety relay and Guardmaster MSR127 single-function safety relay along with a MicroLogix 1400 controller and a PanelView Component operator interface. Self-explanatory HMI screens provide an overview about the state of the machine while advanced diagnostics help save time and moneyon startup and troubleshooting.

Four energy management building blocks assist engineers in configuring energy monitoring applications on low-end machines by providing previously applied examples. With the Plant Power Metering System building block, for example, designers can configure a system to provide a single view of all power meters on the plant floor from one PanelView Component 600 HMI. Energy

The Connected Components Building Blocks (CCBBs) are built around a core of PanelView Component human-machine interfaces, MicroLogix controllers and PowerFlex drives.

Connected Components Building Blocks application development tools help machine builders lower time to market and enhance performance.

Design a Component Infrastructure that

Complements theAutomation Architecture

parameters can be logged, trended and detailed in reports generated in the RSEnergyMetrix® package.

A Simple Motion Control via EtherNet/IP building block allows designers to configure simple motion control applications without the need for a dedicated motion network. Designers can use the Kinetix® 300 EtherNet/IP indexing servo drive with the MicroLogix 1400 to achieve a cost-effective component motion solution.

Another recent CCBB helps machine builders safely monitor the speed of a motor, providing greater flexibility

and efficiency in its safe operation. The Guardmaster MSR57P speed monitoring safety relay connects to a drive and monitors the speed using currently installed encoders. Machine builders can configure this relay to unlock an access door only when the machine is either stopped or when it is at a safe speed. This relay can also monitor an enabling switch to help keep personnel safe while in a hazardous area.

In addition, the Allen-Bradley MultiSight™ Vision Sensor is an alternative to traditional vision systems.

It’s an optical multi-pixel sensor with a pass/fail PNP output. The MultiSight uses four different methods of evaluation to detect or differentiate objects by means of previously defined optical characteristics for separating “good” and “bad” parts.

These and other CCBBs provide machine builders with the information they need to quickly implement common control tasks. What’s more, CCBB tools allow users to help improve machine design and performance whilespending less time engineering the control solution. AT

Check out a sampling of the Connected Components solutions for machine builders:

Allen-Bradley Micro800 Component-Class Micro Programmable Controller®

The new family of Allen-Bradley Micro800™ component-class micro programmable controllers are designed to be used with other Allen-Bradley component class products, such as drives, motion control and operator interface products.

Connected Components Workbench Software

Complementing the new line of Micro800 controllers, the new Connected Components Workbench™ software allows machine builders to program Micro800 controllers and configure other devices in the system, including PowerFlex® drives and PanelView™

Component HMI products.

Allen-Bradley 800B 16mm Push Buttons

The Allen-Bradley® 800B 16 mm pushbuttons help end users reduce maintenance and associated downtime costs with LED pilot lights that can indicate if a motor is in operation and trigger-action emergency-stop (E-stop) devices that cease motion. For more information, visit http://ab.rockwellautomation.com/Push-Buttons-and-Signaling-Devices

Allen-Bradley Kinetix 3 Component Servo Drive

The Allen-Bradley Kinetix® 3 component servo drive provides the flexibility to tailor axes to a machine’s actual power requirement, which will minimise system size and cost. Its compact design makes the drive suited for machines that require less than 1.5 kW and up to 12.55 N-m of instantaneous torque. For more information, visit http://ab.rockwellautomation.com/motion-control/kinetix-3-servo-drive.

Allen-Bradley PanelView Component Terminals

PanelView™ Component Graphic Terminals are panel-mount display devices offering keypad or touch screen options for operator input. Available in a range of sizes from 2 in. to 10 in., these displays are available in color and monochrome versions. For more information, visit http://ab.rockwellautomation.com/graphic-terminals/2711c-panelview-component-terminals.

871TS Inductive and 42CS Photoelectric Stainless Steel Sensors

The 42CS photoelectric sensor and 871TS inductive sensor families withstand the frequent jet-spray washdowns, wide temperature ranges and corrosive cleansing agents commonly used in harsh manufacturing environments such as the food and beverage industry. They offer stainless steel construction, extended

temperature ratings and IP69K enclosure ratings. For more information, visit

http://ab.rockwellautomation.com/Sensors-Switches/Inductive-Proximity-Sensors/871TS-Washdown-Proximity-Sensors and

http://ab.rockwellautomation.com/Sensors-Switches/General-Purpose-Photoelectric-Sensors/Stainless-Steel-Cylindrical-Sensors.

Accelerator ToolkitsRockwell Automation® Accelerator

Toolkits include a full suite of products required to design systems — from a stand-alone MicroLogix™ to a complete Rockwell Automation Integrated Architecture™

system including configuration, visualisation, data acquisition and connectivity to enterprise systems. For more information, visit: http://www.rockwellautomation.com/solutions/integratedarchitecture/resources5.html

The New Allen-Bradley WebsiteFind the latest information about

products, news, events and training on the newly launched Allen-Bradley website. Rockwell Automation has streamlined its online product directory for easy scanning and is offering easier access to popular tools as well as links to support, services, partners and sales information. To discover the new site, visit www.ab.com.

COMPONENTS FOR STAND-ALONE MACHINES



As a developing region, Asia Pacific has weathered the global recession, and industries

in the region are maintaining steady growth.

As such, many of the world’s top drive manufacturers, including Rockwell Automation®, have been increasing their investments in the region. In particular, China is viewed as offering strong opportunities for drives, fueled by growth in industries such as consumer goods, tobacco, construction and machine building.

According to Sam Zhang, standard drive product manager for Rockwell Automation, Greater China, the company has set a goal to become a leader in China’s low-voltage drive market by 2013. The recent introduction of the Allen-Bradley®

PowerFlex® 750 Series AC Drives is helping to achieve that objective.

Drives on a MissionThe PowerFlex 750 Series

offers users a range of control, communications, safety and supporting hardware options. The PowerFlex 753 provides general-

purpose control for applications ranging up to 350 hp and 250 kW while the PowerFlex 755 offers performance ranging up to 700 hp and 450 kW today.

Rockwell Automation launched the PowerFlex 750 Series in China in June 2010. Zhang explains that it integrates many more new concepts in functionality, size and protection level than its predecessors.

For example, drive control modes include adjustable voltage, speed, torque and position in one product to support multiple application types. Selectable, high-performance motor control algorithms with Force Technology include flux vector, permanent magnet motor, sensorless, and V/Hz to support induction and permanent magnet motors.

The PowerFlex 750 Series supports various network protocols to ease integration into users’ architectures. For instance, it features standard embedded Ethernet communication, enabling users to configure, control and collect drive data over EtherNet/IP™ networks. Other network protocols include ControlNet™,

DeviceNet™, Profibus DP, Modbus/TCP and CANopen, among others.

“A DeviceLogix™ control function,” explains Zhang, “controls outputs and manages status information locally within the drive, allowing users to operate the drive independently or complementary to supervisory control.” DeviceLogix also has a built-in capability to forecast diagnostics and follow up with information related to the life cycle of the drive and its motor, which help to prevent unplanned downtime.

Its security solutions – up to Ple/SIL 3, Cat 3 and Cat 4 – help protect the safety of the equipment and personnel. Safety options such as Safe Torque-Off and Safe Speed Monitor provide a choice for safety levels, depending on the application.

Safe Torque-Off, for example, is targeted for safety-related applications requiring removal of rotational power to the motor without removing power from the drive. It offers the benefit of quick start-up after a demand on the safety system and helps reduce wear from repetitive start-up.

The Rockwell Automation PowerFlex 753 and 755 drives help Asia Pacific companies maximise their automation investment.

High-Performance Drives Provide

Flexibility in Motor Control


Safe Speed Monitor is used in applications that can benefit from access to a safety zone where there is limited motion. Users can safely monitor and control the speed of their applications, allowing operators to perform process or maintenance work without stopping the machine.

Zhang notes that the PowerFlex 750 Series features flexibility in its hardware design. The slot-based architecture allows the drives to be built to suit application requirements, and it reduces unnecessary add-ons. Terminal blocks can be pulled apart for easy wiring. In addition, High Horse Power drives in the series are designed

with a roll-in, roll-out inverter and converter for improved serviceability.

Rockwell Automation plans to further develop this series. R&D projects on a four-quadrant drive as well as new methods of increasing the power and efficiency of the existing products are under way.

Zhang adds that Rockwell Automation is not just a supplier of drives but also carries a range of automation products such as programmable automation controllers. “The company provides high-performance and high-quality products and complete system solutions that help customers achieve sustainable, improved production, safety and enhanced competitiveness.”

Staying Warm in WinterOne Chinese company that relies on

the capabilities of the PowerFlex 755 drives is the Daqing Longtang Heat Supply Co., Ltd. (Longtang) in northeastern China, where the average temperatures reach -18.5°C during the coldest months – with lowest temperatures dipping to -39.2°C. The company was initially established to

cover heat demands while another project to construct a power plant was under way. Later, Longtang became responsible for the peak heat source project.

Early in 2010, the company spent US$39 million to construct a 2x58 MW boiler room equipped with circulating fluidised beds covering a total area of about 10 hectares and a construction area of 70,000 sq. meters. Longtang Deputy General Manager Mr. Zhou explains that it is imperative for the automation products to operate in a safe, stable and reliable manner. If heat is cut off due to product quality problems, people will suffer.

For heat-supply projects in Shuangyashan, Jixi and other places, Longtang has been using automation products from Rockwell Automation. Based on the performance of the controllers and drives in use at these sites, Longtang selected Rockwell Automation products, including the PowerFlex 755 drives (700HP), for the Daqing project.

Longtang uses central heating, where water is the heat medium and flows through a thermal network to provide heating to towns, regions or individual users. The heating system that Rockwell Automation and Longtang built together uses 33 PowerFlex 755 drives (see page 10). They are employed in the grate boiler inthe combustion system, coal-feeding machine, blower, fan, circulating pumps and water supply pump. The heating system also includes Allen-Bradley PLCs that automate operations.

Rockwell Automation Marketing Manager for Power Control Mr. Wang points out that system implementation and commission went smoothly on this project, and he attributes it to the drives’ design. “Rockwell Automation,”

he says, “has adopted a user-friendly design of drawers in the PowerFlex 755, with each functional unit located in an individual drawer that is easily pulled in and out. This helps users to perform wire adjustments easily.”

He adds that in addition to the modular design, the drives feature a large power section and a control board with multiple power units. Also, key information is displayed on an LCD screen. If there is any failure, the drive will suggest what the failure might be and how to solve it. What’s more, thanks to powerful networking capabilities, the entire heating system can be connected to the Rockwell

Automation automated monitoring system via the Internet. If a warning or failure occurs, information can be sent to the cell phone of a supervisor.

Mr. Zhou of Longtang adds that Rockwell Automation provides excellent post-sales service as well as customised training and maintenance programs. If the staff encounters any problem during applications, Rockwell Automation can be reached by cell phone at any time. If the problem cannot be solved over the phone, Rockwell Automation will send its service engineers to the site to provide training, troubleshooting or emergency repairs.

Based on satisfied customers such as Longtang, Rockwell Automation is well on its way to achieving the goal of being the third largest supplier of low-voltage drives by 2013. In the 2010 fiscal year, the company achieved more than 30 percent increase in annual growth in China. With a new fiscal year, the company is on track to provide customers with cost-effective solutions and to help them improve their productivity and maximise their investment. AT

Based on satisfied customers such as Longtang, Rockwell Automation is well on its way to achieving the goal of being the third largest supplierof low-voltage drives by 2013.


Toolkit Helps Designers Optimise Machine OperationsRockwell Automation tools and templates save machine builders time in developing control applications.

When it comes to building new machines, original equipment manufacturers (OEMs) are

faced with many challenges. They must select the hardware, determine system layout and wiring, develop logic programming and create the human-machine interface (HMI) application – all of which take time.

For instance, hardware selection involves searching for device selection information from many sources as well as identifying compatible accessories. System layout and wiring entail gathering dimension and wiring information; drawing specific devices; and creating power, control, and communication templates that work with a variety of devices.

Logic programming tasks revolve around controlling and retrieving status and diagnostic data from a variety of devices with different

parameters and tags. In addition, OEMs must standardise machine, application and device logic so that it is easily understood and reused with a variety of applications and devices.

Creating the HMI application requires OEMs to figure out how to access and display status and diagnostic data in a common way from a variety of applications and devices. They must also create standardised control, status and diagnostic displays for ease of use of operators and maintenance personnel.

That is why Rockwell Automation®

offers the Drives and Motion Accelerator Toolkit (DMAT) DVD. It is a collection of tools and templates that helps customers reduce the time and cost of developing a new application using the company’s equipment, especially PowerFlex® AC drives and Kinetix® servo drives. It replaces the

PowerFlex Accelerator Toolkit and the Kinetix Accelerator Toolkit.

A Solid FoundationDMAT allows users to concentrate

on developing the unique features of their Integrated Architecture™

application, not on the routine tasks that add to overhead costs.

The DMAT provides sets of modules built around different needs:

Device modules handle the base needs of drives including communications; commands (start, stop, control, etc.); status monitoring and alarming; and diagnostics.

Application modules are part of the controller logic and focus on tasks such as speed control or camming.

Functional modules address higher-level functions such as machine state control and alarm history management.

The modular format provides control and information for individual products or functions. It allows designers to select specific modules tailored to their needs. Also, the common structure and similar functionality speed understanding and use.

In addition, the modules are designed to work together in a standard format. This format means the designer can add modules as needed with minimal “glue code.” As Rockwell Automation introduces new product and capability modules into the DMAT, they can be easily added to new and existing applications. And, when the standard interface to the modules is understood, the modules can be added to any application.

Taking a TourUsers can gain an understanding of

the power of the DMAT and its tools

WATCHTECHNOLOGY


from the DMAT Quick Start manual. It provides step-by-step guidance on how to use the tools and modules as well as take advantage of them to accelerate machine design.

The first chapter, for example, focuses on architecture and hardware selection. Designers use the Rockwell Automation ProposalWorks™ software to create bills of material for their drives and motion systems. In addition, they are introduced to several Rockwell Automation system configuration tools that provide assistance in sizing motor/drive combinations for a variety of load, transmission and application types.

The second chapter on system layout and wiring enables users to select layout and wiring drawings from a library of drawings in AutoCAD .dwg, .dxf or .pdf formats to start the system drawing set. Those using AutoCAD or AutoCAD Electrical software can take advantage of the drawing editing steps in the chapter. The library’s device wiring references and attributes move with the devices as users edit their power drawing set.

The controller and network configuration chapter provides instructions on how to configure controllers, create a new project file and set up communication for the drive and motion applications. And, the device configuration chapter shows how designers can configure drive and motion hardware by using RSLogix™ 5000 and MotionView OnBoard software.

Logic configuration is the topic of the next chapter, which discusses how designers import preconfigured logic files and edit them for their applications. The toolkit contains preconfigured machine, application and device modules that speed up application logic development. In

addition, the logic modules include control, status and diagnostic codes that provide information to preconfigured operator interface faceplates that can be run on personal computers or PanelView™

Plus terminals.Creating the operator interface

application file for the system is covered in another chapter. The toolkit includes a variety of preconfigured machine and device faceplate displays providing status, control and diagnostics for drive and motion systems. Like the logic modules, the faceplates are designed to be used independently of each other or assembled together based on specific application requirements.

The final two chapters address system commissioning and system application. The system commissioning section guides users in downloading Logix and PanelView Plus applications, preparing and tuning drive hardware, verifying network communications, and verifying general operator and program control. The final chapter walks designers through the preconfigured FactoryTalk®

View Machine Edition application faceplates, explaining the status, control and diagnostic operation of the faceplate displays.

Competitive AdvantageWith the DMAT and its built-in

best practices, system designers are free to focus on the design of their machine control. Rockwell Automation explains that DMAT helps reduce time requirements throughout the machine life cycle.

Some of the savings include:

bill of material, including review of needed accessories and useful options.

Reduced time to develop the initial CAD drawings – including wiring

diagrams and panel layout – to be ready for the specific application additions.

logic program and HMI application – including wiring diagrams and panel layout – to be ready for the specific application additions.

in-the-field troubleshooting. The alarming, monitoring and diagnostic tools included with the DMAT significantly cut the time needed to find and fix problems. And, the HMI screens can be used by operators to provide troubleshooting information over the phone without use of a computer.

DMAT also simplifies system layout and understanding by designers. In addition, it provides a single consolidated library for drive and motion systems. What’s more, it allows more projects to be pursued economically – and for the easy addition and use of new product lines.

The DMAT DVD is available free of charge from Rockwell Automation sales staff and distributors. The same supporting files can be downloaded from the Rockwell Automation Integrated Architecture Tools website. AT

With DMAT and its built-in best practices, system designers are free to focus on the design of their machine control.

on the web

For more information on DMAT, visit: www.ab.com/go/iatools (on the Beyond Getting Started tab)


How Control and Safety Systems Coexist – and Improve OperationsAdvances in integrated safety help further streamline control system designs and costs.

Spurred by advancing technology and changes in industry standards, single-system platforms for safety

and standard control have become easier and more cost-effective than ever to design, implement and maintain. Recent technical improvements now provide automation designers greater flexibility in how they can implement safety systems to help streamline costs and improve productivity.

Economic factors – namely the aim to increase the bottom line without losing sight of safety – are driving the evolution of safety systems from older hardwired solutions to networked systems to contemporary integrated configurations.

According to Tim Roback, Rockwell Automation marketing manager, Safety Systems, Control and Visualisation, the more designers can integrate the

safety functions of a control system with nonsafety functions, the better the opportunity to minimise equipment redundancies, improve productivity and minimise costs. Designers can cut hardware costs because standard and safety portions of the application can share system components.

Without the need for a separate safety controller, integrated safety systems also use a single programming software package. This helps eliminate the need to write and coordinate multiple programs on different controllers, which can simplify applicationprogramming and help reduce training and support costs.

In addition, a single development environment reduces the risk of expensive redevelopment. For example, if a control engineer needs to scale from one line to three, it’s

as simple as porting the necessary application from one to the next.

Fewer components also mean smaller panel enclosures, saving money on control cabinets and floor space.

Integration Via CIP SafetyRoback explains that another

important step in the evolution of integrated safety occurred with the introduction of CIP Safety™. Seamless communication in the past was nearly impossible because no single network could integrate safety and standard control systems while also enabling the seamless transport of data across multiple plant-floor physical networks.

That changed with the Common Industrial Protocol (CIP), an application protocol for industrial networking that is independent of the physical network. The CIP protocol provides a set of common services for control, configuration, collection and sharing across all of the CIP networks – DeviceNet™, ControlNet™

and EtherNet/IP™.In the past, a safety event in one

section of a machine could result in the entire machine shutting down because the standard system had limited knowledge of the safety event.

CIP Safety allows the control and safety systems to coexist on the same network and share data between the safety and standard applications. This enables engineers, for example, to perform zone control where one zone of the machine is brought to a safe state while other zones continue to operate.

Unlike conventional systems, the integration of the safety and standard control systems provides operators and maintenance personnel with visibility to all machine events – including

SAFETY

The Allen-Bradley Compact GuardLogix programmable automation controller (PAC) performs all machine controller functions (including drive, motion and high-speed sequential control) while simultaneously executing SIL 2 and SIL 3 safety functions.


safety events – via the machine or the human-machine interface (HMI). With the insight provided by the integrated system, plant personnel can respond quickly to return the machine to full production.

CIP Safety also minimises the installation of expensive and difficult-to-maintain gateways between each network. Before the development of safety networks, engineers often had to use smaller systems or minimise their performance requirements because it was difficult to hard-wire interlocks and relay-based safety logic into a complete automation system.

Now, engineers can integrate their devices on common physical network segments and allow safety and standard information to flow between devices and controllers.

Next-Generation Safety Control

Recent developments in integrated safety involve leveraging the benefits of a common control platform and extending them into a more compact, scalable form factor. This gives users more design flexibility, allowing them to apply integrated safety functionality across a broader range of applications, including many midrange applications in which a larger controller previously would have been excessive or cost-prohibitive.

“The new Allen-Bradley® Compact GuardLogix® programmable automation controller (PAC) from Rockwell Automation,” says Roback, “performs all machine control functions – including drive, motion and high-speed sequential control – while simultaneously executing SIL 2 and SIL 3 safety functions.

“Developed for midrange applications,” he continues, “the

multidiscipline controller offers designers safety functionality previously found only in larger integrated systems.”

Integrated safety also offers the advantages of a common programming environment, which helps reduce design, configuration, start-up, and maintenance time and costs. With a single software program managing both safety and standard functionality, engineers no longer need to manage the separation of standard and safety memory manually, or worry about partitioning logic to isolate safety.

More Streamlined DesignsThese design productivity benefits

led Amcor, a global packaging manufacturer, to implement a new integrated safety solution at its Revesby, Australia, aluminum can production plant. Previously, standard controllers on the plant’s 11 body-maker and trimming machines were interlocked with a separate hard-wired safety control system. Now 11 individual integrated safety controllers manage them.

An EtherNet/IP connection provides interlocking between machines and links the integrated safety controllers to the factory’s supervisory control and data acquisition (SCADA) system. The combination of distributed I/O and a CIP Safety network helped

reduce site installation and wiring time. The integrated development environment allowed engineers to develop the standard and safety control system code concurrently, which saved significant time.

In addition, with the integrated control architecture already set up, developing and expanding the system is much easier.

Improved Control, Consistency

New software tools, such as high-integrity Add-On Instructions (AOIs), are contributing to even more accurate and efficient safety system designs, notes Roback. AOIs encapsulate code that can be pre-validated modules and easily reused. This promotes consistency between projects, helps simplify debugging and troubleshooting, and minimises the risk of coding errors.

These high-integrity AOIs employ a signature feature to help designers protect data from being altered accidentally or intentionally. The signature feature lets them know whether an AOI definition has been modified. This revision control capability is critical in highly regulated industries where manufacturers need to maintain consistency to meet regulatory requirements and protect intellectual property.

The future of integrated safety points to more options and more flexibility to apply safety technology to meet specific needs. Roback says, “As safety and standard components continue to become more seamlessly integrated into control system designs, implementing safety will no longer be a separate discipline but rather a concurrent and more natural part of the design process. In turn, these innovations will help keep workers and machines safer while boosting profits.” AT

on the web

For more information on safety, visit: www.rockwellautomation.com/solutions/safety

The more designers can integrate the safety functions of a control system with nonsafety functions, the better the opportunity to minimise equipment redundancies, improve productivityand minimise costs.

Amcor, a global packaging manufacturer, employs the Allen-Bradley GuardLogix controller to integrate safety and conventional control within one platform.


The manufacturing sector is emerging from the economic downturn. Many company leaders

have experienced an increase in growth and profits by running their businesses differently. They’vediscovered the value of partnerships that lead to short- and long-term growth. As the Board on Manufacturing and Engineering Design described in its Visionary Manufacturing Challenges for 2020 report, manufacturing “companies [in the year 2020] will be aggregations of people connected to each other bymutual trust and supported by an alliance…infrastructure.”

Indeed, one of the new realities you’re facing is a shift from a “company vs. company” style of competition to “network vs. network.” The strength of your company’s network, including its upstream and downstreampartners, will ultimately determine your ability to survive and compete.

To help you keep pace with demand and implement the most efficient, effective automated manufacturing systems available, the Rockwell Automation®

PartnerNetwork™ provides a critical resource. Member companies in the PartnerNetwork offer access to the domain knowledge of thousands of experts in industries, applications, technologies, services and geographies around the world.

You can take advantage of the network to get your products and services to market faster, reduce total cost of ownership, use energy and plant-floor assets more effectively, and minimise risks.

Guiding PrinciplesThe foundation of the

PartnerNetwork framework is built on three themes common in business, yet effective only through practice:

1. Trust2. Collaboration3. Shared business values

These principles guide every facet of the program, from defining and selecting partners to delivering scalable, best-in-breed solutions that address each of your specific challenges. These themes translate into automated solutions not found with any other supplier.

Here is how trust, collaboration and business value are defined in the context of the PartnerNetwork program:

Trust. The cornerstone of the PartnerNetwork framework is trust, defined as strategic intent, open communications and mutual respect. Rockwell Automation and its partners share a commitment to doing what is best for customers: exchanging best practices, developing leading-edge solutions and working together to solve customer challenges.

However, earning trust between partners takes work. It requires a mutual understanding of rewards gained from doing business together, executed seamlessly in the eyes of customers and supported throughout the solution’s life cycle. You benefit from trusted partnerships when you achieve maximum production efficiency and reduced risk.

Collaboration. Collaboration means building multi-level relationships and executing coordinated planning, sales and marketing among the partners.

Rockwell Automation believes that no individual organisation, no matter how big or knowledgeable, can command all the relevant technologies needed to be successful. The PartnerNetwork program offers a wealth of well-managed

The strength of a manufacturer’s partnering network bringsbusiness value and competitive advantage.

The Power of Partnering

PartnerNetwork™

Produc fe e

T

Strateg Product Refeff rence

Technology LiTT censing

Distributors

Solution Providers

Machine Builders

Business Enterprise Sales & Solutions Products & Technologies

Enterprise Solution Partners

The Rockwell Automation PartnerNetwork is an extensive community of partner companies that specialise in implementing and servicing Rockwell Automation solutions and complementary technology.


relationships established to create customised, best-in-breed solutions for customers, regardless of size or location.

Shared Business Values.Partner companies associated with the PartnerNetwork share a common customer-first value, leading to best-in-class solutions and market differentiation as an alternative to the one-sise-fits-all approach to business.

Indeed, it takes discipline to manage multiple partners, which is why Rockwell Automation has established criteria for each partner type. Each member of the PartnerNetwork is invited to join the program only after Rockwell Automation has vetted the partner’s capabilities and establishes that the partner is committed to meeting industry and local standards and conducts business ethically.

This way, you can be assured you’re working with partner companies that have a vested interest in collaborative relationships proven through hundreds of successful applications worldwide.

A Network Approachto Business

Rockwell Automation has maintained collaborative, trusted and mutually beneficial business relationships for years. In fact, its network of independent

distributors that carry out the majority of the company’s sales transactions began in the 1920s.

The types of companies with whom Rockwell Automation collaborates fall into one of three categories:

Business enterprise partnersinclude strategic alliance partners and enterprise solution providers who work with Rockwell Automation to develop, connect and deploy production systems that enable true plant-wide and enterprise-wide optimisation. These partners share product development plans and technologies, and often bring industry-specific knowledge required for many automation projects.

Sales and solutions partnersinclude distributors and solution providers. They partner with customers throughout the decision-making process to design, implement and support their automation investment. Machine builder partners provide high-quality, innovative machinery that features the latest in Rockwell Automation technology.

Product and technology providers include Encompass™ third-party product referencing program participants and companies that license Rockwell Software® solutions, hardware and firmware products to offer Rockwell Automation-enabled solutions. Collectively, these partners deliver proven technology that seamlessly integrates with Rockwell Automation to solve manufacturer application challenges.

Rockwell Automationand Microsoft

The strategic alliance between Rockwell Automation, the leader in manufacturing intelligence, and Microsoft, the global leader in business intelligence, is a prime example of the PartnerNetwork framework principle of collaboration.

The two companies have embarked upon a series of joint initiatives to gain insight into the unique challenges

you face. For example, “envisioning workshops” provide an opportunity for engineers from each company to “whiteboard” and brainstorm solutions for solving specific customer problems. In addition, joint sales engagements encourage collaboration between operations and IT leaders.

“Voice of the customer” events offer a forum for customers to involve both companies in discussions that help identify collaborative solutions to manufacturing issues. At these events, customers have expressed a need for more advanced reporting and analytics to extend the investment they’ve made in the dozens of legacy systems

currently managing their manufacturing operations.

As a result, Rockwell Automation and Microsoft worked together to develop a unique solution that integrates Rockwell Software FactoryTalk®

VantagePoint technology with Microsoft’s business intelligence platform, SharePoint Server 2010 PerformancePoint Services.

For example, a global consumer product goods manufacturer implemented the solution to integrate its plant-floor quality, maintenance, scheduling, manufacturing execution system (MES), inventory, consumer complaints, Hazard Analysis and Critical Control Point (HAACP) and lab systems into one reporting and analytics framework.

As a result, the company has connected more than 140 disparate manufacturing systems in 59 plants around the world. It has more than two million data items configured in its model and 10,000 synchronisations – all running on one server. It’s using the data to better equip each of its users with real-time decision support and ad-hoc analytics for continuous improvement.

The resulting solution provides unprecedented visibility into operational data while leveraging and optimising existing IT investments.

Partnering for Your SuccessLeveraging the power of partnerships

is more critical than ever. The best-in-breed solutions offered by Rockwell Automation and its extensive community of partners offer you a competitive edge, combined with the confidence that comes from working with a single-source supplier. Rockwell Automation leaders truly believe that when we successfully collaborate with and among partners, we collectively devise the best long-term solution for you. AT

on the web

For more information on the Rockwell Automation PartnerNetwork, visit:

www.rockwellautomation.com/partners

The strength of a manufacturer’s network will ultimately determine its ability to survive and compete.


FOCUSPRODUCT

CENTERLINE Motor Control Centers Integrate Embedded EtherNet/IP Capabilities

EtherNet/IP capabilities have been added to the Rockwell Automation® CENTERLINE® motor control centers (MCCs). The EtherNet/IP-enabled MCCs enable users to access more detailed production data, ultimately resulting in higher asset availability, improved productivity and reduced maintenance costs.

Leveraging a single, standard network simplifies communication for

configure and collect data from any point in the system. In addition, by taking advantage of Premier Integration, users can configure and

™ 5000 software, reducing the risk of errors associated with redundant programming.

The Ethernet connection also allows CENTERLINE MCC users to access information remotely. This allows personnel to monitor,

dangerous conditions and power equipment.Designed to meet global standards, CENTERLINE low-voltage

MCCs offer a rugged, high-performance packaging solution to meet manufacturers’ needs. With embedded IntelliCENTER® technology, the CENTERLINE MCCs use a preconfigured and pretested network with integrated hardware and software. This level of integration helps reduce installation time with its plug-and-play setup and can help minimise facility downtime by providing intelligent diagnostic and predictive failure information.

For more information, visit:http://ab.rockwellautomation.com/Motor-Control/Motor-Control-Centers

Power Range Extendedfor the Allen-Bradley PowerFlex755 AC Drives

The power range of the Allen-Bradley® ® 755 AC drives has

them well-suited for motor control applications in heavy industries such as oil and gas, tire and rubber, refining, material handling, metals and mining.

The roll-out capability allows access to the drive for fast installation and maintenance. The drive’s modular design helps simplify replacement of drive components such as cooling fans, circuit boards and major subassemblies. This modularity also allows the drive’s converter and control pod to remain in the unit while the inverter is rolled out, so control wiring can remain connected. In addition, the control pod in this drive can be mounted remotely for hassle-free access to low-voltage control and diagnostics.

Advanced diagnostic capabilities include indication of blown fuses and blown surge protectors. Monitoring and tracking of operating data on cooling fans, I/O relay cycles and motor run times also provide data for preventive maintenance, helping to reduce unplanned downtime.

port and five option slots that allow users to tailor the drive to best suit their application. Options include I/O, feedback, safety, additional communications

® Integrated Motion, allowing it to be configured and controlled using motion profiles and

® controller with Rockwell

drives, motion drives, I/O, smart actuators and other EtherNet/IP-connected

performance and reduce engineering costs.The power range

AC drive offering from 0.75 kW/1 hp up to 450 kW/700 hp at 400/480 VAC input, providing robustness,

and performance in a single product family.

For more information, visit: http://ab.rockwellautomation.com/drives/powerflex-755ab.rockwellautomation.com/drives/powerflex-755

FOCUSPRODUCT


Optimise Machine-LevelData Collection for Manufacturing Intelligence

The latest release of FactoryTalk® Historian Machine Edition (ME) version 2.2 software provides native connectivity to the OSIsoft PI system, enabling PI System users who employ Allen-Bradley® ® controllers to now have an off-the-shelf, machine-level historian application that can easily transfer historical data to their on-site or enterprise-wide PI System.

Manufacturers can collect data in remote or hasardous locations as well as when speed and reliability are crucial, such as in oil and gas, mining,

pharmaceutical or water treatment applications. Machine builders can apply FactoryTalk Historian ME to pre-qualify the data collection of their machines, reducing the time required for on-site installation, configuration and validation.

Users also have more control over when data is transferred, which can save time and reduce costs. A machine-level historian can be programmed to transmit data to avoid peak-usage hours, or can be remotely directed to halt and restart transfer if vital information needs to be prioritised.

For more information, visit:http://discover.rockwellautomation.com/historian

New Safety Relay Line fromRockwell Automation

A new family of Allen-Bradley® Guardmaster® safety relays can help machine builders and end users simplify safety relay selection and reduce component inventory and life cycle costs. The line includes basic units capable of supporting a range of safety devices in various applications, such as single and multi-zone configurations.

The relay line features a patented, single-wire communication capability that helps eliminate the need for dual-channel connection between relays.

single wire to connect devices. This provides for a reduction in installation

the front of the relay, yielding a variety of configurations including regional and global e-stop architectures.

A universal input feature allows devices, such as safety interlock switches, emergency stop switches and safety mats, to use the same set of input terminals on the relay. This helps eliminate the need to employ a specific safety relay for a specific type of input device, helping simplify system design and reduce hardware costs.

modules, providing users with twice the functionality of a standard relay in a 22.5 mm housing while reducing wiring for faster commissioning. A single TÜV-approved rotary switch with internal redundancy eliminates the need for double switches, helping to speed configuration while addressing multiple functions such as reset modes and time delays.

Below is an overview of the new safety relays:Guardmaster DI/DIS

be configured in a variety of safety functions for zoning and muting

safety connectionGuardmaster SI

safety device

safety connectionGuardmaster CI

layout to legacy Allen-Bradley Guardmaster MSR safety relays and other brands of safety relays

safety connectionGuardmaster EM/EMD

of base module

The family is designed to meet new functional safety standards such as EN

Rockwell Automation® provides a comprehensive family of safety products. These include safety interlock switches; emergency stop and enabling switches; prosafe trapped key interlock systems; presence-sensing safety

For more information, visit:http://ab.rockwellautomation.com/safety


PanelView Plus 6 Human-Machine Interfaces Enhance Visibility into Machines and Production Lines

FactoryTalk View Machine Edition 6.0 Speeds Development TimeFactoryTalk® is an integral element of the

Rockwell Automation® visualization solution. The updated software adds new features that speed development time by up to 30 percent while enhancing the functionality and impact of human-machine interface (HMI) applications for machine-level, PC-based operator interface solutions.

The new features include:

and compelling displays in less time.

common.csv file format.

be deployed in up to 20 languages – including Chinese, Japanese and Korean – without cumbersome font-linking.

maintenance users can download to a PanelView™ Plus HMI without having to install and have a license for FactoryTalk View Studio.

For more information, visit:www.rockwellautomation.com/rockwellsoftware/performance/view/viewme.html

FOCUSPRODUCT

The Allen-Bradley® PanelView™

(HMIs) are designed for applications that require monitoring, controlling and displaying information in dynamic ways, where operators must quickly understand machine status and make better decisions.

Recently introduced terminals – ranging in screen size from 7 in. to 15 in. in touchscreen, keypad, keypad and touchscreen, including conformal coating and Marine-certified models – feature more memory with faster refresh rates

supports graphics enhancements along with larger application runtime files,

to get to the screens and data they need faster, avoiding errors and improving their ability to respond. These changes, along with the following feature

® ViewPoint server

run-time application

Edition (ME) and FactoryTalk ViewPoint software running on a Windows CE

corruption in a closed system that does not require a shutdown procedure. EtherNet/P is the standard network.

For more information, visit:http://ab.rockwellautomation.com/graphic-terminals/2711p-panelview-plus-6-terminals

Contact DATA-LINC today:[email protected]

+1-425-882-2206

3535 Factoria Blvd SE Suite 100Bellevue, WA USA

Or visit us on the web : www.data-linc.com

The

one-stop source for your

data communication needs

Access Real-Time Data through an Internet BrowserFactoryTalk® ViewPoint 2.0 software enables users to access information

when and where they need it. As a Web-enabled human-machine interface

dashboards to users for improved real-time decision-making. Since it is a thin-client configuration, there is no client software to install and maintain, thus lowering total cost of ownership.

supports high-quality and scalable graphics, full animation and real-time updates. Core features in the browser include graphics objects and controls, embedded variables, pop-up displays and parameters. New in Version 2.0 is support for numeric/string entries and commands.

Users can easily navigate forward and backward; use favorites for quick access to critical information; use tabs to organise displays in a browser window; collaborate with co-workers via hyperlinks; and access previously viewed displays using History. In addition, graphics displays automatically resize and scale to fit the browser window. Applications run on various client devices without design-time modification.

FactoryTalk ViewPoint 2.0 employs Microsoft Silverlight, a cross-browser, cross-platform plug-in for delivering rich interactive applications for the Internet. FactoryTalk ViewPoint 2.0 supports these Microsoft 32-bit operating systems: Microsoft Windows 7 Professional/XP/Vista and Microsoft Windows Server 2003/2008. It also supports

servers include FactoryTalk View Site Edition Network and FactoryTalk View Site Edition Local Station, PanelView™

PanelView Plus.

For more information, visit:www.rockwellautomation.com/rockwellsoftware/performance/viewpoint

FOCUSPRODUCT

Where Automation Connects™ www.prosoft-technology.com/fi eldserver-slotserver

(AP Rep) Offi ce – Malaysia

Tel: +603.7724.2080

Email: [email protected]

Building Automation In-Rack Communication Modules…

The new ieldServer ateways off er even more

connectivity for Building Automation Systems:

Lon or s

…and Gateways

ProSoft Technology is now the e clusive provider of the SlotServer

Lon or s

ire Alarm

Building Automation

Systems (BAS)

Contact your ProSoft Technology

representative for pricing and

availability.

AutomationToday 2011 Aug-Oct

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