Integrated, Intelligent Motor Control Centers

Integrated, Intelligent Motor Control Centers

Industry Overview
The goals for any commercial or industrial process are simple: minimize overall costs and enhance productivity. To achieve these goals, processes require better monitoring, less downtime, and faster maintenance. Obtaining real-time process information requires integrating hardware, software, and communications. Communication and advanced sensing technologies now exist at the device level, and recent enhancements make a completely integrated solution both usable and affordable. Motor control centers (MCCs) occupy a prominent role in control schemes, housing a comprehensive array of control and monitoring devices. MCCs have moved rapidly to include the latest component technologies and integrating these advanced technologies presents a major opportunity to transform islands of data into useful information that minimizes downtime. This paper focuses on technology integration methods in MCCs, and quantifying associated costs and benefits.

Historical Progression
MCC Benefits
The benefits of MCCs are well documented and proven by the approximate $1.5 billion USD global market. These benefits include: Quicker installation at a lower cost with its own power bus and factory-wired and tested units, field wiring and testing are minimized. Saves floor space compared to individually mounting the same devices Reduced planning and downtime - standardized sections and units simplify design and training; plug-in units can be easily replaced and rearranged Expandability sections and units can be added to existing MCCs Increased level of safety fault containment is part of MCC design, and units can be easily unplugged to service at a workbench, away from hazardous voltages Faster delivery entire system arrives ready to install as a single entity, with no additional design or components to coordinate Serviceable with power ON at adjacent starters the inherent isolation of MCC units makes it possible to work on a given unit without de-energizing any adjacent units, and still conform to code and OSHA requirements

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Traditional Electromechanical Components

Traditionally, MCCs contained only electromechanical components and all connections were hardwired. These components remain the workhorses even today, with over half of all MCC units containing only electromechanical devices. Advances in solid-state technology ushered in a revolution in control systems with intelligent devices that could be programmed to do more than just turn a motor on and off. These smart components found a warm reception in MCCs, and soon AC drives, soft starters, programmable logic controllers (PLC s), and electronic overload relays were standard offerings in MCC units. Integration was accomplished through hard wiring to an I/O Chassis. For a detailed discussion of issues and costs associated with interwiring in MCCs, refer to Appendix A.

Solid-State Components

Networked Components

The advent of device-level communication networks brought new possibilities for advanced monitoring, control, and diagnostics. These networks also greatly simplified wiring, eliminating the bundles of control interwiring and corresponding complex interwiring diagrams. Although early MCC network communication brought benefits, there were also some challenges: Reliability and flexibility shortcomings in the daisy chain drop-line architecture connecting units to the main trunk line. Adding new units or accidental breaks in the chain affected any downstream units in that connection, potentially shutting down equipment. Safeguarding exposed trunk line and drop line cables in the wireways, when pulling and installing other power cables. Establishing initial network communications with MCC unit devices. Separating power and communication cables to meet code requirements. In confined wireways, adequate separation was difficult at best.

Integrated, Intelligent Motor Control Centers

Integrated, Intelligent MCC

The network communication challenges revealed a need to integrate the three major system components: the communications, the hardware, and the software. These next generation, integrated, intelligent MCCs are current technology. The design streamlines installation, set-up, and changes; delivers real-time monitoring of the MCC; and easily integrates into a facility-wide network. The questions for todays users are: What is the extra cost to buy an integrated, intelligent MCC? What are the real advantages and benefits for my facility vs. potential headaches and extra cost?

The following section highlights some issues that a user should consider.

Key Issues To Consider When Evaluating an Integrated, Intelligent MCC

Different Elements vs. a Standard MCC
An integrated, intelligent MCC will contain some different elements in both the sections and the units, plus software. These can be categorized as: the built-in communication media, intelligent motor control components, and MCC monitoring software. Keep in mind that an MCC may not be an integrated, intelligent MCC, just because it includes these elements. The early versions of MCCs with communication networks contained variations of these elements. The major distinction is that there was not a harmonized design that deliberately integrated the communication network, hardware, and software. A standard MCC ships without interwiring, and requires extensive interwiring, documenting, and testing in the field. The integrated, intelligent MCC arrives ready to install, pre-tested and preconfigured; the communication cables are installed and tested, the intelligent devices are pre-programmed (with baud rate, node number, trip current, etc.), and the software screens are pre-configured. The following sections review important considerations for the elements outlined above, and provide a framework for evaluating potential integrated, intelligent MCC offerings.

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Built-in Communication Network

The communication network needs to be analyzed with respect to both the network performance and the physical construction. Proven, open communication network The trend toward open networks (as opposed to proprietary networks) is clear, and the advantages are well documented. So how do you choose an open network? The following criteria form a useful checklist. DeviceNet is evaluated as an example of an excellent open network choice. Criteria Throughput Cost per node DeviceNet Up to 500 kbps communication rate Low node cost, due to high production volume of controller area network (CAN) chips Proven noise immunity (refer to Publication 1485-WP001A-US-P) Both flat and round Class 1, 8A, 600V cabling available DeviceNet products are offered by over 300 suppliers, with over half a million installed nodes

Immunity to typical MCC noise Cable rated for use adjacent to power wiring Accepted by a wide range of suppliers and users

Optimized Physical Construction The obvious approach for routing network cables in MCCs is through the horizontal and vertical wireways. Although this method has been successful, the opportunity exists for a more optimized solution. Trunk lines and drop lines isolated behind barriers Avoids potential damage to communication cables during installation and maintenance activities. Independent, easy-connect ports on drop lines The ideal configuration provides independent ports, readily accessible, to simplify installing, withdrawing, relocating, and adding plug-in units. This configuration replaces the daisy-chain architecture, where moving or adding an MCC unit required interrupting the chain and disabling downstream units.

Integrated, Intelligent Motor Control Centers

Droplines behind barriers or vertical wireway

Trunkline behind barriers

Individual network ports accessible in vertical wireway

Intelligent Motor Control Components

To qualify as an intelligent MCC, every unit even the nonintelligent ones - must have communication capability. This is necessary in order to replace the traditional control interwiring with a single communication wire. Ideally, all the units should also have input points to monitor devices like the disconnect switch, contactor, overload relay, or a hand-off-auto selector switch. A network scanner module or network linking device must also be provided to collect and distribute the device data in the MCC. An integrated, intelligent MCC should have at least the following components available. Intelligent overload relays The most common device in the MCC is the motor starter, so overload relay intelligence is paramount. Users should expect: Built-in network communication Input points (for monitoring disconnect or selector switch) Output points (for controlling contactor) LEDs for status indication

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Protective functions thermal overload, underload, jam, current imbalance, stall, phase loss, zero sequence ground fault, and PTC thermistor input. Programmable parameters for the protective functions - trip level, warning level, time delay, and inhibit window. The ability to program these features avoids the nuisance trips that often led to users disabling protective functions. Warning alarms alert users to a potential trip, and allow actions to avert impending downtime. Time delays and inhibit windows allow recognition of abnormal current loads (e.g. extended starting times with high currents), without nuisance tripping. Current Monitoring phase, average, full load, ground fault, imbalance percent, and percent thermal capacity used are important monitoring features. Diagnostics device, warning, and trip status; time to overload trip; history of last five trips; time to reset. Miniature I/O module for non-intelligent units Traditional electromechanical starters and feeder disconnects have no means to communicate with networks. Wiring to a distant I/O chassis is not the ideal solution. The preferable solution is an I/O module within the unit small enough so that the MCC unit size is not altered - to link the device and the network. The I/O module should have an adequate number of inputs and outputs, according to the unit functions. For a starter, four inputs and two outputs satisfy 99% of applications. Network communication interface module with input points Intelligent devices often require an external communication module. Ideally, this module should contain input points (again, to eliminate wiring to a distant I/O chassis). Four inputs are sufficient for most applications.

MCC Monitoring Software

Integrated, intelligent MCCs have dedicated software that delivers a window into the motor control center and related equipment. MCC software eliminates creating costly customized MCC screens within operator interface software, yielding a plug and play solution usable by computer novices. The following checklist identifies benchmarks for integrated, intelligent MCC software. Operates in a familiar environment The software will be easiest to use if it behaves according to known operating environments, e.g. Windows. Includes unique MCC documentation to initialize screens Every MCC is unique. The application program, upon installation, should access specific information to generate screens containing data pertinent to that MCC.

Integrated, Intelligent Motor Control Centers

Initiates network communication Establishing devices as recognized entities on a network can be the most time-consuming step. In the optimal situation, the MCC manufacturer downloads user-specific information like node addresses (per user specification or a standard scheme), and baud rate, then tests the entire system for accurate functions and communication. Upon installing the MCC and software, the user only needs to sit back and let the software poll the pre-configured devices to match the device information with the user database. Displays pre-configured screens showing most common parameters Intelligent MCC software can access the users specific data files and build the corresponding screens. The following pre-configured software screens are useful: MCC line-up (elevation) view Realistic dynamic display that shows unit type, nameplate information, and status of units. Unit View Supplies dynamic information about the unit and network device. Parameters of greatest interest are already shown, and can be changed if necessary. Data can be displayed digitally, on meters or trend graphs. Event Logging Automatically logs preset and user-defined faults and warnings, and accepts manual entries such as maintenance activities and equipment updates. Spreadsheet View Ideal for viewing the most information at a glance. Sorting and filtering capabilities help users organize pertinent data.

Includes all user-specific documentation A comprehensive documentation database minimizes frustration and downtime experienced while trying to locate misplaced documentation. Valuable documentation components are: Unit wiring diagrams As-built drawings of the MCC line-up Product user manuals Spare parts list Databases should allow users to add and change information, especially wiring diagrams.

Can be accessed at any network level The user should be able to view the MCC by plugging into any network level, such as DeviceNet, ControlNet, or Ethernet. This feature gives the user flexibility to locate the software on a maintenance laptop, in a control room, or at an engineers desk.

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System Design and Testing

Component and systems tests should have been performed, with demonstrated compliance results readily available. The following tests assure that integrated, intelligent MCCs will function as expected and required. Design verification tools - Designing networks requires a thorough understanding of the associated rules and parameters. A software design tool should be available to verify if critical network and design parameters have been met. Such software simplifies the entire design, order, and installation process. Electrical and environmental testing - a full battery of tests, both individual components and when installed as a system include. Noise immunity IEEE qualification tests Showering arc Electric drill Walkie-talkie Overload jogging Short Circuit UL component and cable qualification Shock and vibration Seismic Completed system testing verify: Cable system integrity DeviceNet module communication Network baud rate and node numbers Software content

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Integrated, Intelligent Motor Control Centers

Efficiently handles MCC changes and upgrades MCCs often have units added and rearranged, so the software must readily accommodate such data changes. The software should easily handle new units (with corresponding data information disks), and any location changes for existing units. Where users must supply information, step-through "wizards are the preferred method, since they guide the process.

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Cost Comparison
How much extra does an integrated, intelligent MCC cost? The answer requires careful definition of MCC equipment to be compared in the cost analysis. For example, it is not logical to compare a standard unwired MCC to an integrated, intelligent MCC. An appropriate analysis compares an MCC interwired with an I/O chassis, to an integrated, intelligent MCC. Both are complete interwired and tested systems, and both provide basic monitoring and control. The study evaluates costs for three versions of MCCs: an MCC interwired to a larger, advanced function PLC I/O chassis; an MCC interwired to a smaller, basic function PLC I/O chassis; and an MCC with DeviceNet cabling and necessary DeviceNet hardware. Two versions of PLCs were used to account for size, function, and cost differences over a wide scope of PLC offerings. The study consists of two parts: a variable size analysis that compares costs as the number of units and sections increases (from 10 starters to 50 starters) with varying numbers of inputs; and a specific comparison of costs for a sample representative MCC line-up (eight sections). For simplicity, the variable size analysis includes one version of a full-voltage non-reversing (FVNR) starter unit added repeatedly. The sample representative MCC allows a check on the reasonableness of the variable size analysis, and is a more realistic representation of a typical MCC line-up.

General Assumptions for All Cases

The study only includes actual manufacturer equipment and wiring costs. Any charges associated with pre-order and postshipment activities are assumed common and equal, and are excluded. The study does not include costs for mechanical installation of MCCs. Common costs for all three methods are not included, e.g. wiring diagrams, any engineering and drafting charges, network software, PLC programming software, and any dedicated equipment software. For the study, these costs are assumed to be common and equal. Sections are 20 (508 mm) wide, 15 (381 mm) deep, NEMA Type 1, with 800 ampere copper main power bus with tin plating, and a x 1 horizontal ground bus. FVNR starter units contain a circuit breaker disconnect with an internal normally open auxiliary contact; transformer control; red and green pilot lights; solid-state overload relay; and one normally open and one normally closed auxiliary contact mounted on the starter.

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Integrated, Intelligent Motor Control Centers

Case 1 Class II MCC with a Larger, Advanced Function PLC I/O Chassis

Specific Case Assumptions PLC unit has an eight-slot chassis, power supply, distributed I/O adapter module, and modules included for inputs and outputs. For the trend comparison, when the eight slots are exceeded, another PLC unit is added. All inputs and outputs are isolated in accordance with transformer control in the units. 16-input and 16-output modules are included, reflecting typical user practices. For the trend comparison, when the 16 inputs or outputs are exceeded, an additional module is added.

Case 2 Class II MCC with a Smaller, Basic Function PLC I/O Chassis

Specific Case Assumptions PLC unit has a seven-slot chassis, power supply, distributed I/O adapter module, and modules included for inputs and outputs. For the trend comparison, when the seven slots are exceeded, another PLC unit is added. All inputs and outputs are isolated in accordance with transformer control in the units. 8-input and 8-output modules are included, reflecting typical user practices. For the trend comparison, when the eight inputs or outputs are exceeded, an additional module is added.

Case 3 MCC with DeviceNet Cabling

Specific Case Assumptions DeviceNet cabling is 8 ampere, 600 Volt, Class 1, behind barriers, with connectors in the vertical wireway. DeviceNet nodes are configured. Every FVNR starter unit contains a miniature I/O module with 4 inputs and 2 outputs. Linking device permits seamless communications from ControlNet to DeviceNet. No PLC unit is required. 8 ampere DeviceNet power supply included.

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Variable Size Analysis

Additional Assumptions The process to determine comparative costs consists of: Assume an initial line-up containing ten (10) size 1 full-voltage nonreversing starter units in sections, and a PLC unit to accommodate inputs and outputs. Add Size 1 FVNR starter units individually up to a total of 50. Include extra PLC units as required for inputs and outputs. Provide adequate sections to house all units. Six (6) size 1 FVNR starter units per section. One output required for each coil. Three permutations were performed for the inputs, using two, three, and four inputs. Inputs are typically used to monitor: Contactor Overload relay Unit disconnect switch Hand-off-auto selector switch The following graphs illustrate the comparative costs for DeviceNet and Class II MCCs as the number of FVNR starter units increases. The three Class II lines on each graph correspond to varying numbers of inputs. Refer to Appendix B for sample data point calculations used to produce the graphs .

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Integrated, Intelligent Motor Control Centers

Cost Analysis for DeviceNet MCC vs. MCC Interwired to a Larger, Advanced Function PLC I/O Chassis

$150,000

$130,000

Smaller jump when another section is added

$110,000 MCC List Price

$90,000

$70,000

Class II I/O 2 Inputs/Unit Class II I/O 3 Inputs/Unit

$50,000

Large jump when another PLC chassis is added

Class II I/O 4 Inputs/Unit DeviceNet w/4 Inputs/Unit

$30,000 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50

Total Number of FVNR Starter Units

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Cost Analysis for DeviceNet MCC vs. MCC Interwired to a Smaller, Basic Function PLC I/O Chassis

$170,000

$150,000

Smaller jump when another section is added

$130,000

MCC List Price

$110,000

$90,000

$70,000

Class II I/O 2 Inputs/Unit Class II I/O 3 Inputs/Unit

$50,000

$30,000 10 12 14 16 18 20 22 24

Large jump when another PLC chassis is added

26 28 30 32 34 36 38

Class II I/O 4 Inputs/Unit DeviceNet w/4 Inputs in Unit

40

42

44

46

48

50

Total Number of FVNR Starter Units

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Integrated, Intelligent Motor Control Centers

Findings and Conclusions

The DeviceNet MCC cost is nearly identical to a motor control center interwired with an I/O chassis. The choice, therefore should be based on technology preference, not price. As expected, the networked solution becomes more cost effective as the amount of information returned per MCC unit (i.e. number of inputs) increases.

Representative MCC Comparison

Additional Assumptions
All details listed under both the General Assumptions and the Specific Case Assumptions apply. MCC line-up includes eight NEMA Type 1 sections, with 800 ampere tin-plated copper main power bus, x 1 horizontal ground bus, two power bus splice kits, two ground bus splice kits FVNR starter unit quantities and sizes: (10) Size 1 (9) Size 2 (7) Size 3 (4) Size 4 (1) Size 5 Lug provision included for main incoming lines, rated 800A Starter units have three inputs (3I), one output (1O) Total Inputs 93 Total Outputs 31 Larger, advanced function PLC requires two I/O chassis Smaller, basic function PLC requires three I/O chassis MCC with DeviceNet contains a unit with a DeviceNet to ControlNet linking device and one 8 ampere DeviceNet power supply unit

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Price Comparison
MCC interwired to MCC interwired to a larger, advanced a smaller, basic function PLC I/O function PLC I/O chassis chassis Sections Main lug provision Starter Units Network communication interface module in each starter unit Power supply unit PLC unit of linking device unit Doors Class II wiring Network Cabling Total List Price $13,722 672 65,983 -$13,722 672 65,983 -MCC with DeviceNet $13,722 672 65,983 21,700

-25,160 72 10,561 -$116,170

-31,692 108 11,218 -$123,395

2,400 6,000 144 -8,000 $118,621

Prices derived using published list prices

Total Price Comparison for Representative MCCs

$130,000 $120,000 $110,000 $100,000

Communication interface module, power supply unit, network cabling Class II wiring

Total Price

$90,000 $80,000 $70,000 $60,000 $50,000 $40,000

PLC or Linking Device unit

Sections, splice kits, Main lug, starter units, doors MCC Interwired to MCC Interwired to DeviceNet MCC Large I/O Chassis Small I/O Chassis

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Findings and Conclusions

The DeviceNet MCC price falls nearly at the midpoint between the two versions of motor control centers interwired with I/O chassis. The cost relationships correspond closely to the previous variable size analysis results.

Summary
Integrated, intelligent MCCs substantially simplify wiring, troubleshooting, rearranging units, and adding sections and units. They also provide new information that can be used to minimize downtime, facilitate monitoring of MCCs and related equipment, and decrease repair time.With the diminishing cost of intelligence, they should be strongly considered for all applications.

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Appendix A Case Study for Factory-interwired I/O Chassis

This white paper uses a factory-interwired MCC as the basis for comparison to the DeviceNet MCC. Is this valid? Wouldnt a fieldinterwired MCC be a better basis? The factory-interwired pricing was chosen because it is lower than the price for field interwiring. A previous white paper documented the price comparisons. An excerpt follows. ---------------------------Since 1980, more than 50,000 sections of MCCs have been interwired to PLCs. The old concern about packaging logic devices in proximity to high voltage has been sufficiently laid to rest by the overwhelming success of these installations. The question still surfaces as to who can interwire MCC units to the PLC modules most cost-effectively: the MCC manufacturer or a local contractor/panel shop. A major engineering construction firm wanted to determine the answer, and conducted an independent study that evaluated costs of interwiring PLC I/O chassis to motor control center units. Their study compared costs for both an MCC manufacturer and an electrical contractor to do the interwiring. The comprehensive study was based on an actual user order that needed an MCC and PLC chassis with 320 I/O points, to control a manufacturing process with 25 motors. The study focused on three methods for interwiring the motor control center and PLC chassis, and reviewed costs to supply engineering, design, and construction necessary to provide, install, and make the equipment operational. The three methods were: Case 1 Electrical contractor (panel shop) designs, assembles, and interwires PLC chassis located in a separate programmable control cabinet to an MCC. Case 2 Electrical contractor (panel shop) interwires PLC chassis located in an MCC. Case 3 Motor control center manufacturer interwires PLC chassis located in an MCC, making it a factory-interwired MCC.

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Integrated, Intelligent Motor Control Centers

General Assumptions for All Cases

PLC I/O modules included for 160 inputs and 160 outputs. All I/O are wired from PLC chassis to terminal blocks total of 640 wires, 1280 terminations. 25 output points are wired from the terminal blocks to motor starter coils total of 50 wires, 100 terminations. 25 input points are wired from the terminal blocks to motor starter auxiliary contacts total of 50 wires, 100 terminations. Remaining 270 I/O (135 inputs, 135 outputs) are for field devices and are located in the MCC for convenience. Terminations are pressure-plate type and do not require wire lugs. PLC cabinet or MCC sections sized for four I/O chassis (three are purchased, one future space). Hardwired emergency-stop relays and control relays (total of 24) are wired to terminals, and are located in a dedicated MCC compartment. Internal MCC interlock wiring consists of 48 interlocks (two per relay) total of 96 wires, 192 terminations. Completion criteria for I/O wired to starters: Each PLC output shall be energized, the unit control circuit tested, and feedback from the starters auxiliary contact received at the input module.

Services and Materials Provided

Each case included estimates for engineering, drafting, materials, and installation. Specific case descriptions are identified below. The following services and materials were provided by others and are common to all three cases. They are not included in the cost analyses: Engineering MCC single-line diagram and MCC arrangement I/O assignments to load and inputs Elementary wiring (schematic) diagrams for I/O and hardwired emergency stop and control circuits

Material and Construction Costs MCC incoming power PLC programming software Wiring from field devices and motors to MCC and PLC I/O terminals

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Case 1 MCC and Separate Programmable Control Cabinet Wired by Electrical Contractor

Specific Case Assumptions The PLC I/O chassis and I/O terminals are located in a separate, freestanding NEMA 12 cabinet designed specifically for the system (to include three I/O chassis with 320 digital I/O). The PLC cabinet is located 10 feet (3 m) from the MCC (requires 20 feet [6.1 m] of conduit, 30 feet [9.1 m] of wire). Interconnecting wiring between the PLC and MCC will be #14 AWG THHW / THWN copper wire routed in rigid galvanized steel conduit. Five 2-inch (50.8 mm) conduits with (128) #14 AWG wires each, will be routed between the MCC and PLC cabinet. Electrical contractor to wire I/O card wiring arms to the terminal strips.

Engineering Deliverables PLC cabinet layout drawing with bill of material. Plan drawing showing location of MCC and PLC cabinet, and conduit routing. Interconnection wiring diagram showing wiring between PLC and MCC. Specify and purchase MCC. Specify and purchase labor and materials for interwiring between the PLC cabinet and MCC units.

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Case 2 Programmable Controller in MCC Wired by Electrical Contractor

Specific Case Assumptions The assumptions are identical to Case 1, except: The PLC I/O chassis and I/O terminals are located in dedicated sections in the MCC. I/O card wiring arms are wired to terminal strips by the MCC vendor.

Engineering Deliverables Specify and purchase MCC that includes I/O chassis, terminal blocks, and relays. Specify and purchase labor and materials for interwiring between the PLC section and MCC units.

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Case 3 Programmable Controller in MCC Wired and Tested by MCC Manufacturer

Specific Case Assumptions The assumptions are identical to Case 2, except: MCC manufacturer makes all interconnections between the PLC I/O chassis and MCC (facotry interwired MCC).

Engineering Deliverables Specify and purchase MCC that includes I/O chassis, terminal blocks, relays, and all interwiring (factory interwired MCC).

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Conclusion

This independent study shows that Case 3 has the lowest interwiring cost- i.e. where the MCC manufacturer mounts and wires I/O in the MCC (factory interwired motor control center). The study data, combined with other factory interwired advantages like reduced start-up time, high quality wiring, and high quality documentation - support the trend toward increased purchases of factory interwired motor control centers.

Cost Breakdown - Case Study

Case 1 Labor Costs Physical Design of PLC Cabinet and Control Room 2 AutoCAD Drawings-Panel Layout, COntrol Room Elec. Design of PLC Cabinet and Interconnection Interdiscipline Coordination, Quality, Management, Drawing Review 2 AutoCAD Drawings-Interconnection, Wiring Management, Scheduling, Meetings RFQ Creation/Analysis Assembly & Installation of P:LC Cabinet (incl. wiring to terminal blocks) Inspection(s) and Travel Expense Mechanical Installation of MCC Wiring Between MCC and PLC, Checkout Relay Interlock Wiring Field Start-Up Assistance TOTAL LABOR COSTS $ 5250 2500 5000 2500 1680 1680 2820 6284 3920 1500 9570 588 2400 $ 45, 692 --$ 5000 2500 1080 1680 1440 -1960 2000 4836 588 2400 $ 23, 484 ----$ 840 1260 1440 -1960 2000 --960 $ 8,460 Case 2 Case 3

Material Costs Motor Control Center Enclosure, PLC Components, Terminal Blocks, Panduit, Etc. Relays for Safety Interlock Wiring (and conduit) Between MCC and PLC TOTAL MATERIAL COSTS 44436 24797 72 1706 $ 71, 011 73992 -72 276 $ 74, 340 81391 ---$ 81, 391

TOTAL COSTS

$ 116,703

$ 97,824

$ 89,851

Rockwell Automation provided prices for: Case 1 MCC and PLC component Case 2 MCC with PLC (PLC price included in MCC price) Case 3 MCC with PLC in MCC wired and tested

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Appendix B Sample Data Point Calculations for Variable Size Cost Comparison Graphs
The tables show data points used to generate the graphs found in the Variable Size Cost Comparison section. All prices were derived using published list prices. Details about FVNR units, input and output modules, PLC units, sections, splice kits, and doors are included in the General Assumptions and Specific Case Assumptions on pages 10-12. MCC with Larger, Advanced Function PLC
# of Units
10 15

# of # of Inputs Outputs
20 30 40 50 60 70 80 90 100 30 45 60 75 90 105 120 135 150 40 60 80 100 120 140 160 180 200 10 15 20 25 30 35 40 45 50 10 15 20 25 30 35 40 45 50 10 15 20 25 30 35 40 45 50

# of # of # of PLC # of Input Output Chassis Sections Modules Modules

2 2 3 4 4 5 5 6 7 2 3 4 5 6 7 8 9 10 3 4 5 7 8 9 10 12 13 1 1 2 2 2 3 3 3 4 1 1 2 2 2 3 3 3 4 1 1 2 2 2 3 3 3 4 1 1 1 1 1 2 2 2 2 1 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 3 3 2 3 4 5 6 7 8 9 9 2 3 4 5 6 7 8 9 9 2 3 4 5 6 7 8 9 10

PLC Total
$11,157 11,157 14,762 16,185 16,185 25,919 25,919 27,342 30,947 $11,157 12,580 16,185 17,608 25,160 28,765 30,188 31,611 35,216 $12,580 14,003 17,608 26,583 28,006 31,611 33,034 42,009 45,614

Unit Total
$15,260 22,890 30,520 38,150 45,780 53,410 61,040 68,670 76,300 $15,260 22,890 30,520 38,150 45,780 53,410 61,040 68,670 76,300 $15,260 22,890 30,520 38,150 45,780 53,410 61,040 68,670 76,300

Section Total
$3,352 5,028 6,704 8,380 10,056 11,732 13,408 15,084 15,084 $3,352 5,028 6,704 8,380 10,056 11,732 13,408 15,084 15,084 $3,352 5,028 6,704 8,380 10,056 11,732 13,408 15,084 16,760

Splice Kit
0 0 157 157 157 314 314 314 314 0 0 157 157 157 314 314 314 314 0 0 157 157 157 314 314 314 471

Door
0 36 72 108 144 108 144 180 0 0 36 72 108 72 108 144 180 0 0 36 72 36 72 108 144 108 144

Sub Total
$29,769 39,111 52,215 62,980 72,322 91,483 100,825 111,590 122,645 $29,769 40,534 53,638 64,403 81,225 94,329 105,094 115,859 126,914 $31,192 41,957 55,061 73,306 84,071 97,175 107,940 126,185 139,289

Interwiring Adder
$2,977 3,911 5,222 6,298 7,232 9,148 10,083 11,159 12,265 $2,977 4,053 5,364 6,440 8,123 10,509

Total
$32,746 $43,022 $57,437 69,278 79,554 100,631 110,908 122,749 134,910 $32,746 44,587 59,002 70,843 89,348 115,603

2 Inputs per Unit 3 Inputs per Unit

20 25 30 35 40 45 50 10 15 20 25 30 35 40 45 50 10 15

9,433 103,762 11,586 127,445 12,691 139,605 $3,119 4,196 5,506 7,331 8,407 10,794 $34,311 46,153 60,567 80,637 92,478 118,734

4 Inputs per Unit

20 25 30 35 40 45 50

9,718 106,893 12,619 138,804 13,929 153,218

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MCC with Smaller, Basic Function PLC

# of Units
10 15 20 25 30 35 40 45 50 10 15 20

# of # of Inputs Outputs
20 30 40 50 60 70 80 90 100 30 45 60 75 90 105 120 135 150 40 60 80 100 120 140 160 180 200 10 15 20 25 30 35 40 45 50 10 15 20 25 30 35 40 45 50 10 15 20 25 30 35 40 45 50

# of # of # of PLC # of Input Output Chassis Sections Modules Modules

3 4 5 7 8 9 10 12 13 4 6 8 10 12 14 15 17 19 5 8 10 13 15 18 20 23 25 2 2 3 4 4 5 5 6 7 2 2 3 4 4 5 5 6 7 2 2 3 4 4 5 5 6 7 1 1 2 2 2 3 3 3 4 1 2 2 3 3 4 4 4 5 2 2 3 3 4 4 5 5 6 2 3 4 5 6 7 8 8 9 2 3 4 5 6 7 8 9 10 2 3 4 5 6 7 8 9 10

PLC Total
$9,991 10,982 18,364 20,973 21,964 29,346 30,337 32,946 40,328 $10,982 18,728 21,337 29,710 31,692 40,065 41,056 43,665 52,038 $17,737 20,710 29,083 32,683 40,429 44,029 51,775 55,375 63,748

Unit Total
$15,260 22,890 30,520 38,150 45,780 53,410 61,040 68,670 76,300 $15,260 22,890 30,520 38,150 45,780 53,410 61,040 68,670 76,300 $15,260 22,890 30,520 38,150 45,780 53,410 61,040 68,670 76,300

Section Splice Total Kit

$3,352 5,028 6,704 8,380 10,056 11,732 13,408 13,408 15,084 $3,352 5,028 6,704 8,380 10,056 11,732 13,408 15,084 16,760 $3,352 5,028 6,704 8,380 10,056 11,732 13,408 15,084 16,760 0 0 157 157 157 314 314 314 314 0 0 157 157 157 314 314 314 471 0 0 157 157 157 314 314 314 471

Door
36 72 72 108 144 144 180 0 0 36 36 72 72 108 108 144 180 180 0 36 36 72 72 108 108 144 144

Sub Total
$28,639 38,972 55,817 67,768 78,101 94,946 105,279 115,338 132,026 $29,630 46,682 58,790 76,469 87,793 105,629 115,962 127,913 145,749 $36,349 48,664 66,500 79,442 96,494 109,593 126,645 139,587 157,423

Interwiring Adder
$2,864 3,897 5,582 6,777 7,810 9,495 10,528 11,534 13,203 $2,963 4,668 5,879 7,647 8,779 10,563 11,596 12,791 14,575 $3,635 4,866 6,650 7,944 9,649 10,959 12,665 13,959 15,742

Total
$31,503 42,869 61,399 74,545 85,911 104,441 115,807 126,872 145,229 $32,593 51,350 64,669 84,116 96,572 116,192 127,558 140,704 160,324 $39,984 53,530 73,150 87,386 106,143 120,552 139,310 153,546 173,165

3 Inputs per Unit 4 Inputs per Unit

2 Inputs per Unit

25 30 35 40 45 50 10 15 20 25 30 35 40 45 50

MCC with DeviceNet

# of PLC # of # of Units Chassis Sections Module with 4 inputs in Unit 10 15 20 25 30 35 40 45 50 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 7 8 9 PLC Total 6,000 6,000 6,000 6,000 6,000 6,000 6,000 6,000 6,000

Unit Total Splice Kit 22,260 33,390 44,520 55,650 66,780 77,910 89,040 100,170 111,300 0 0 157 157 157 314 314 314 314

Door 0 36 72 108 144 180 0 36 72

Total $33,612 $47,454 $61,453 $75,295 $89,137 $103,136 $114,086 $127,928 $141,770

Comparison of Total Costs

Total for MCC Interwired to Large I/O Total for MCC Interwired to Small I/O Chassis Chassis # of Units 2 Inputs 10 15 20 25 30 $32,746 $43,022 $57,437 $69,278 $79,554 3 Inputs $32,746 $44,587 $59,002 $70,843 $89,348 4 Inputs $34,311 $46,153 $60,567 $80,637 $92,478 2 Inputs $31,503 $42,869 $61,399 $74,545 $85,911 3 Inputs $32,593 $51,350 $64,669 $84,116 4 Inputs $39,984 $53,530 $73,150 $87,386 $33,612 $47,454 $61,453 $75,295 $89,137 % Difference for MCC with DeviceNet vs. MCC Interwired to Large I/O Chassis % Difference for MCC with DeviceNet vs. MCC Interwired to Small I/O Chassis 3 4 Inputs Inputs 3.1% -7.6% -5.0% -7.7% -15.9% -11.4% -16.0% -13.8% -16.0% -14.4% -18.1% -16.7% -18.1%

DeviceNet Total

2 Inputs 2.6% 10.3% 7.0% 8.7% 12.0% 2.5% 2.9% 4.2% 5.1%

3 4 2 Inputs Inputs Inputs 2.6% 6.4% 4.2% 6.3% -0.2% -0.6% -1.3% 0.4% 1.6% -2.0% 2.8% 1.5% -6.6% -3.6% -3.5% -3.9% -7.8% -7.5% 6.7% 10.0% 0.1% 3.8%

1.0% -10.5% -1.2% -11.2% -1.5% -10.6% 0.8% -9.1% -2.4% -11.6%

$96,572 $106,143

35 $100,631 $103,762 $106,893 $104,411 $113,192 $120,552 $103,136 40 $110,908 $115,603 $118,734 $115,807 $127,558 $139,310 $114,086 45 $122,749 $127,445 $138,804 $126,872 $140,704 $153,546 $127,928 50 $134,910 $139,605 $153,218 $145,229 $160,324 $173,165 $141,770

Publication Number 2100-WP001A-EN-P December 2000

Copyright 2000 Rockwell Automation, Inc. All Rights Reserved.