Ay 2014 Elec Systems Ebook

Electrical systems are the heart of any
production system. Learn about best

practices for variable-frequency drive
maintenance, drive system conguration,
motor energy efciency, worker safety
and cost efciency.
Special Report on
Electrical
Systems
WWW.ROCKWELLAUTOMATION.COM/THEJOURNAL
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TABLE OF CONTENTS
AD INDEX
4 STEPS TO REDUCE HIDDEN COSTS IN ELECTRICAL SYSTEMS 4
Learn how facility managers can improve power efciency and quality to minimize
electronic equipment malfunctions and downtime.
HOW TO MEASURE OUTPUT VOLTAGE FROM A VFD TO A MOTOR 6
Learn the step-by-step measurement sequence for assessing variable-frequency drive output
factors when troubleshooting electrical signals.
VIDEO: PRESSURE CALIBRATION TOOLS SERVE UNIQUE NEEDS 8
RIGHT-SIZE YOUR MOTION CONTROL SYSTEM 13
Mechatronic design tools and scalable control solutions help manufacturers optimize
energy efciency and lower total cost of ownership.
TAKE THE PAIN OUT OF DRIVE SYSTEM DESIGN AND START-UP 15
Drives conguration software that focuses on ease-of-use tools can enhance motor-drive
installation and save time and labor during conguration, commissioning and setup.
WEBINAR: EPLAN/RSLOGIX - CLOSING THE GAP BETWEEN
HARDWARE & SOFTWARE DESIGN 16
HOW TO IMPROVE LOTO SAFETY 19
Learn how permanent electrical safety devices help protect workers from arc ash
and other hazards in accordance with NFPA 70E and OSHA requirements.
VIDEO: INFRARED INSPECTION TECHNOLOGY HELPS PROTECT WORKERS
FROM ELECTRICAL HAZARDS 21
HARVEST THE CORRECT CURRENT 24
Discover how a fertilizer manufacturer uses Insulated Gate Bipolar Transistor technology
to solve variable-frequency drive cable problems.
EPLAN SOFTWARE & SERVICE 3
www.rockwellautomation.com/go/p-eplan
SERVICE WIRE 18
www.rockwellautomation.com/go/p-servicewire
GRACE ENGINEERED PRODUCTS 26
www.rockwellautomation.com/go/p-grace
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4 STEPS TO REDUCE HIDDEN COSTS
IN ELECTRICAL SYSTEMS
Learn how facility managers can improve power efciency and quality to minimize electronic
equipment malfunctions and downtime.
>>
Low power factor and high levels of voltage
and current harmonic distortion are signifi-
cant but often hidden costs in industrial operations.
Without corrective measures, these factors increase
electrical utility charges, impair equipment health and
prevent efficient industrial expansion.
Further complicating these efects, devices that correct
a low power factor can introduce negative interaction
with harmonic-distortion producing loads, causing elec-
tronic equipment malfunctions and related downtime.
As a result, facility managers should take steps to
improve power efciency and quality, and increase their
return on energy investments.
Power Factor Basics
Defned as the ratio between real power measured in
kilowatts (kW) and apparent power measured in kilovolt-
amperes (kVA), power factor is a dimensionless number
between 0 and 1, often expressed as a percent. It mea-
sures how efectively a specifc load consumes electrical
energy to produce work. Te higher the power factor, the
more efective the use of electrical capacity; the converse
also is true.
For example, imagine a facility operating at 5 MW
with a power factor of 0.5. To get 5 MW of real power at
0.5 power factor, 10 MVA of apparent power needs to be
transferred (5 MW 0.5 = 10 MW).
Clearly, low power factor has real energy cost conse-
quences. More energy costs more money. In addition,
electrical utilities often will add penalty charges to users
that have low power factor below a certain threshold.
Tese charges add up over time, resulting in signifcant
amounts of wasted money every year. To avoid these
charges and improve power efciency and quality, man-
gers should take the following four steps:
Step 1: Examine the
Electrical Utility Charges
Te frst step facility managers should take to correct
the power factor is to examine the utility bill, which will
state exactly how much extra the utility charges each
month for a low power factor. Managers should review
how much theyre paying for power in kilowatt hours.
Ten they should see if theyre charged for kilovar
demand and if a power-factor penalty is included. Tese
charges might be labeled under apparent power demand,
reactive energy surcharge or kilovar demand.
Step 2: Integrate Power Monitoring
and Corrective Devices
Once they understand the system-wide fnancial costs, fa-
cility managers should use power monitors to continuously
assess the facilitys power factor to determine if they have a
low power factor. Monitoring needs to be continuous, be-
cause the power factor changes over time as loads turn on
and of. If the facility manager uncovers a consistent, low
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power factor, he can calculate the size of a fxed or static
capacitor bank to install and correct the power factor.
He may uncover a variable power factor in which
parts of the facility that use motors powered across the
line have a low power factor, but other parts that use
variable-frequency drives (VFDs) have a high power
factor. If so, he should consider installing power control
with removable levels of capacitance, depending on how
and when conditions change.
Dynamic control is critical in variable power factor.
Facilities have many loads that turn on and of at difer-
ent times, and managers need to be able to respond to
the resulting changes in power factor.
Te opposite of lagging power factor is a leading
power factor, meaning that the facility returns reactive
power to the electrical utility while still being charged
for it. For example, leaving capacitors on while electrical
loads are turned of can cause leading power factor. In
this case, the utility may reduce the power-factor penalty,
but the facility still wastes money.
Facility managers need to keep their power factor on
middle ground to have the right balance of efciency
with right-size equipment, no penalty charges and no
power returning to the utility company.
Step 3: Minimize Harmonic Distortions
Once managers have examined the facilitys power factor
and integrated capacitance, they need to evaluate any
related nonlinear loads that create harmonic current
and voltage distortion. Combating a low power factor
by adding capacitance is efective. However, nonlinear
loads, such as VFDs, and even computer equipment with
switched-mode power supplies, can interact with power
factor capacitance and create a resonance condition,
resulting in severe voltage and current distortion.
Without proper mitigation, harmonic currents and
voltage distortion can lead to equipment malfunctions,
including power transformer and power factor capaci-
tor overheating and failure, and equipment overvolt-
age faults. Facility managers can monitor the level of
harmonics with power-monitoring devices and examine
the total harmonic distortion or the individual harmon-
ics on the system.
Data from power monitors can include available
amperage and the demand for amperes in the facility.
If consumption is signifcantly close to the total avail-
able, harmonic distortion could be afecting the facilitys
electrical equipment or ability to expand. It also could be
adding to the electrical utilitys surcharge for the power
factor.
Once the level of harmonic distortion is identifed, fa-
cility managers need to decide how impactful of an issue
it is. Reducing distortion can reduce harmonics, and also
help correct the power factor. Depending on the gravity
of the problem, facility managers can mitigate harmonic
currents with harmonic flters added to the incoming
power, including 18-pulse transformers, passive flters
and active flters.
Step 4: Continue to Monitor
Te levels of power factor and harmonic distortion will
determine system-wide efciency and production. Facil-
ity managers should continue to monitor both after cor-
rection and mitigation. Tey can add or remove capaci-
tance or flters to reach the middle ground thats ideal for
their facility. With these four steps, facility managers can
identify and rectify hidden costs.
For more information on energy-management and energy-
monitoring solutions, visit http://goo.gl/VtyfL.
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HOW TO MEASURE OUTPUT VOLTAGE
FROM A VFD TO A MOTOR
Learn the step-by-step measurement sequence for assessing variable-frequency drive output
factors when troubleshooting electrical signals.
By Hilton Hammond, Fluke Corp.
>>
When troubleshooting the electrical signals
within a motor/drive system, think of it in
terms of input vs. output. A variable-frequency drive
(VFD) transforms the input mains of constant voltage
and frequency into a voltage and frequency range that
can be varied to control motor torque.
Troubleshooting at the input starts with testing power
supply and quality. Troubleshooting at the output starts
with measuring that transformed voltage and frequency.
Tis article steps through the measurement sequence for
assessing VFD output:
DC Bus.
Output voltage/current/frequency.
Unbalance.
Volts/hertz ratio.
Output refections.
Figure 1 illustrates the components of a VFD input
Figure 1. Envisioning a motor/drive system as three segments input, output and load helps clarify what specic measurements and troubleshoot-
ing steps to take in each segment.
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AC-to-DC converter and output pulse width modu-
lated (PWM) signal, with the DC link in-between. In
a VFD, the PWM inverter regulates both voltage and
frequency to the motor. Te voltage and frequency to
the motor is varied by modulating the width of the
output pulses, which is accomplished by controlling the
semiconductor switch.
Te input diodes provide constant DC bufer for the
switching inverter section, equivalent to 1.414 times the
peak of the input voltage. Te capacitor acts as a flter to
reduce ripple in the DC section.
Te control devices in the inverter section usually are
insulated gate bipolar transistors (IGBT), and nowadays
have enough power to handle loads up to 500 hp.
Step 1: Measure DC Bus Voltage
An oscilloscope can be used to measure the absolute
value of the rectifed DC voltage; when AC coupled, it
Figure 2. Connecting an oscilloscope to measure negative DC and
positive DC buffer voltage.
Figure 3. These show an example of DC-coupled versus AC-coupled waveform traces from an oscilloscope used to inspect overall DC and ripple
voltages.
+ DC -
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also can be used to zoom into the
signal to view the extent of ripple
(see Figure 2).
Measure the DC bus voltage
across the + and terminals us-
ing oscilloscope or DMM.
Use AC or DC input coupling
to measure the absolute or ripple
voltages.
Make sure the scope and probe
are rated appropriately to mea-
sure the voltage level.
Interpreting DC Bus
Measurements
Te DC bus voltage is relative
to the peak voltage of the mains
input.
>> VIDEO: Pressure Calibration Tools Serve Unique Needs
In this video, Jim Shields from Rockwell Automation Encompass
TM
Product Partner
Fluke Corp. highlights a few of the 32 new pressure calibration tools the company
introduced at the 2013 Automation Fair
event. They include the model 719 Pro that

measures up to 300 psi.
Fluke also introduced its 721 Duel-Range Pressure Calibrator for oil and gas
industry measurement for custody transfer calibration. This tool measures the low-
pressure value across the blockage inside a pipe known as an orifice plate, the
high-pressure measurement inside the pipeline, and the precision temperature so
that the user can calibrate a flowmeter.
Watch the video now!
T1 T2 T3
T1
T2
T3
Figure 4. Use an oscilloscope with appropri-
ate safety-rated electrically isolated inputs
to perform differential measurement on the
three-phase output.
Figure 5. Measure the current through each
phase using appropriately rated current
clamps.
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DC bus voltage is ~1.414 x the
rms line voltage. For example,
for a 480VAC drive, the DC bus
should be ~678VDC.
A DC voltage value that is too
low can cause the drive to trip.
At the cause, the mains input
voltage is probably too low, or
the input sine wave might be
distorted by fat topping.
If the ripples peaks have a dif-
ferent repetitive level, one of
the rectifer diodes is possibly
malfunctioning (this is load
dependent). Ripple voltages
above 40V can be caused by
malfunctioning capacitors or a
drive rating that is too small for
the connected motor and load
(see Figure 3).
Step 2: Measuring Voltage
and Unbalance
Use an oscilloscope with a V
PWM function connected be-
tween the three motor terminals
(see Figure 4).
Compare the scope readings
to the drives display values.
Voltage drop between drive
and motor terminals should not
exceed 3%.
Unbalance greater than 2% is
problematic.
Use a multichannel oscillo-
scope to check for motor volt-
age unbalance across the three
output phases.
Measure the voltage on each
terminal, and record each
measured voltage for use in the
next step.
Measure voltage unbalance at
full load.
Step 3: Measuring Current
Unbalance
Use an oscilloscope with a current
clamp on all three drive output termi-
nals separately to measure the current
draw on each terminal (see Figure 5).
Constant
7.67 V/hz
Constant Torque
Extra Torque
at Start-Up
Extra
Torque
from Higher
Voltage
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
Constant
7.67 V/hz
Constant Torque
Extra Torque
at Start-Up
Extra
Torque
from Higher
Voltage
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
Constant
7.67 V/hz
Constant Torque
Extra Torque
at Start-Up
Extra
Torque
from Higher
Voltage
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
V
o
l
t
a
g
e

(
V
)
Frequency (Hz)
0 30 60
460
230
0
Figure 6. Voltage and frequency in constant-torque variable- hp applications can be measured easily to verify proper drive programming
and motor operation.
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Because the current measurement will be made in a
high-energy, electrically noisy environment, be sure to
use the proper current clamp. If your test setup doesnt
automatically evaluate unbalance, see the sidebar at left
about manually calculating unbalance.
Te level of unbalance should not exceed 10%.
For every 1% of voltage unbalance, motor current
unbalance will be 3% to 4%.
If voltage unbalance is low, then excessive current
unbalance could indicate shorted motor windings or
phases shorted to ground.
Generally, current unbalance for three-phase motors
should not exceed 10%.
Voltage unbalance will result in current unbalance.
If the voltage unbalance is within acceptable limits,
then any excessive current unbalance detected could
indicate shorted motor windings or
one of the phases shorted to ground.
Step 4: Volts/Hertz Ratio
Te ratio of voltage to frequency, measured in hertz,
determines the amount of torque produced by an AC
induction motor. By keeping this ratio constant, the
magnetic feld inside the motor is kept at a constant level.
Tis results in a constant torque.
Above the nominal frequency of 60 Hz, the voltage
will not increase anymore, and the torque will decrease
(see Figure 6).
To measure volts/hertz ratio, use a digital multimeter
with a V PWM option, where V PWM refects the am-
plitude of the fundamental frequency, or an oscilloscope.
Te oscilloscope should simultaneously display the
frequency of the PWM output and a voltage comparable
to the motor nameplate rating (see Figure 7).
Use a current clamp to measure the frequency. It
If you manually measured voltage or current, the next step
in determining if there is a voltage unbalance is to calculate
the percentage unbalance.
Determine the voltage or current average.
Calculate the largest voltage or
current deviation.
Divide the maximum deviation by the average voltage or
current and multiply by 100.
This results in a percentage of voltage or current unbal-
ance for the supply voltage to the drive input. Heres an
example:
% unbalance = (Max deviation from average V or I/average V
or I) x 100
Example:
30 + 35 + 30 = 95
95/3 = 31.7 average current
35 - 31.7 = 3.3 maximum deviation
3.3/31.7 = .104
.104 x 100 = 10.4% current unbalance
In this example, the current unbalance is 10.4%. Depending
on the rating and impedance of the circuit, this either could be
acceptable or a big problem. If the load current is close to the
rated current for the circuit, high levels of unbalance can cause
nuisance breaker tripping.
Consideration: A manual unbalance calculation is a point-
in-time determination of voltage or current unbalance. A power
quality analyzer will show voltage or current unbalance in real
time, including any variations in unbalance.
>> Manually Calculate Unbalance
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should be ~7.6 for 460V motor,
~3.8 for a 230V motor.
Step 5: Output Reections
Ref lections occur as a result of an
impedance mismatch or change in
the current transmission path (see
Figure 8). In a motor drive circuit,
the peak of the ref lection could
be as high as the DC bus voltage
level.
To use an analogy, consider
what happens to a garden sprin-
kler when the f low of water is
momentarily changed by someone
stepping on the rubber hose. The
pressure at the sprinkler head
changes, peaking as the built-
up pressure is released. Using an
overly long cable (>100 ft.) also
can result in ref lections along the
length, measurable as transients.
Te refection itself manifests as
spikes on an oscilloscope display in a
range of waveforms, amplitudes and
durations. As a rule of thumb, refec-
tions or transients >50% of nominal
voltage are problematic.
One possible solution includes
shorting the conductors between
the motor and inverter. Another
solution is to increase the grade of
cabling, thus reducing the imped-
ance or switching to Inverter Rat-
ed Motors with a higher insulation
value of 1,600V or greater that can
withstand the transients.
Most ref lections are caused by
fast switching DC voltage by the
IGBTs (dV/dt). The IGBT is an
element of the drive that func-
tions like a very fast on/off switch.
The IGBT outputs DC voltage
as a PWM signal on an induc-
tive load. This causes very high
inductive voltages over a very short
(switching) time, also referred to
as dV/dt. The IGBT has a built-in
free-wheel diode to compensate for
this. However, transients are vis-
ible when the oscilloscope glitch
detect setting is switched on.
Measuring and Interpreting
Output Reections
Most digital multimeters dont
have the sample rate and frequency
bandwidth to detect short, fast out-
T3
T2
T1
T1 T2 T3
Figure 7. Setup for connecting the oscil-
loscope input to measure output voltage and a
current clamp to measure output frequency.
Captured
Waveform
Tolerance
Envelope
Voltage
Waveform
Figure 8. Note the voltage spikes on the trailing edge of this pulse width modulated signal, as
captured by an oscilloscope.
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put transients. For this reason, use an oscilloscope con-
nected to the motor terminals as illustrated in Figure 3.
Te B input trace in Figure 9 demonstrates how ex-
cessive refections appear in waveform view. Knowing
what a particular distortion looks like helps reduce the
time necessary to identify root cause.
Minimal Downtime
Determining the cause of motor drive system failures re-
quires systematically performing tests and measurements
at key points in the system. Specifcally regarding power
supply, diferentiate between power input and output
and apply both diferent measurement techniques and
evaluation criteria at each. With a little knowledge, those
measurements can guide troubleshooting to the true
cause, bringing the system up as quickly as possible.
Fluke Corp. is a participating Encompass Product Part-
ner in the Rockwell Automation PartnerNetwork. Based
in Everett, Wash., Fluke Corp. manufactures, distributes
and services electronic test tools.
Fluke Corp.
www.rockwellautomation.com/go/p-uke
Rockwell Automation Encompass Product
Partner Program
www.rockwellautomation.com/go/tjencompass
Figure 9. This shows an oscilloscope screen capture of a PWM drive. signal
with excessive reections (B input trace).
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>>
Manufacturers always are looking to improve
energy efficiency, which also improves their
profitability. Those who are successful seldom go it alone
they enlist help from their machine and equipment
builder (OEM) partners.
Whether developing a simple or complex machine, an op-
timized design is critical for creating equipment that not only
runs with greater efciency, but also quickly adapts to market
changes and integrates with upstream and downstream op-
erations. By leveraging mechatronic design tools and scalable,
right-sized automation, OEMs can develop the sustainable,
energy-efcient systems manufacturers need.
Mechatronic Design Tools
Mechatronics is a multidisciplinary design approach
relying on the collaborative application of motion
design software and products. Using this approach,
mechanical, electrical and control engineers can easily
analyze, simulate, optimize and select motion-control
systems through virtual prototyping.
Tese digital simulations help engineers fnd errors
early in the design process. Furthermore, engineers
can input design information in a familiar environ-
ment and understand how their design decisions afect
the system as a whole, allowing them to quickly evalu-
ate alternatives and select the best ft.
For example, an electrical engineer at a garage door
manufacturer simulated a motion application and
found the drive running at 90%. He automatically
thought, Wow! I am using almost all of my torque.
Te motor I have chosen is the right size. However,
the mechanical engineer had selected an oversized
gearbox with a pulley system to convert rotary to
linear power.
When the engineers re-simulated the application using
Motion Analyzer software from Rockwell Automation
to build the application from the ground up, they were
forced to ask, How much energy is required to just move
the garage door, taking out all the steps we think we need
to get there? Meaning, they didnt need to measure how
much power was needed to run an inefcient gear box.
Te software suggested they use a lower kilowatt-rated
linear thruster motor. Because the kilowatt rating on the
motor translates to a larger drive as well, reducing the
motor size removed energy losses coming from a series of
oversized and unnecessary components. Energy usage for
the application as a whole was cut in half.
Mechatronic design software, such as Motion Ana-
lyzer from Rockwell Automation, helps OEMs obtain the
benets of a mechatronic design approach by allowing
engineers to conduct a virtual design review and identify
opportunities to optimize the efciency, performance and
size of the solution.
In the past, determining right-size system components
was so time intensive it proved prohibitive. Now, infor-
mation to design and build a more efcient, cost-efective
machine is available at an engineers fngertips. Further-
more, the new design programs are changing machine
building by enabling OEMs to fnd performance limita-
tions in a virtual environment.
Te programs take performance and Total Cost to
Design, Develop and Deliver
SM
into account even before
the commissioning phase begins to ofer faster and more
cost-efective solutions to design and sustainability issues.
RIGHT-SIZE YOUR
MOTION CONTROL SYSTEM
Mechatronic design tools and scalable control solutions help manufacturers
optimize energy efciency and lower total cost of ownership.
By Michael Cromheecke, Marketing Manager for Kinetix Motion Business, Rockwell Automation
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Evaluate Tradeoffs
Design programs, such as Motion Analyzer and
SolidWorks a 3D mechanical CAD program from
Dassault Systmes can work together to evaluate the
tradeofs between materials, size and safety of compo-
nents, and available motion systems. Tis helps OEMs
keep machines small and energy-efcient.
In the past, the appropriate sizing of a mechatronics
solution could only be verifed after the machine was
built. Te time required to consider alternatives prohibit-
ed optimization and as a result machines were frequently
overbuilt. Now machine builders can conduct engineer-
ing analysis on the mechatronics solution in a virtual en-
vironment prior to physically building the mechanisms.
Tis not only speeds the time to develop but also allows
for a more optimized solution.
For example, Motion Analyzer software can analyze
energy costs to run a machine for a year and how
much money more energy-efcient products can save
you. Te software computes load weight with motion
profle how far and fast a load must travel. It can then
compute energy spend per axis when users input cost of
kilowatt hours (kWh) and machine uptime for one year.
Take a rotary motor machine that runs on 11-cent-per-
kilowatt-hour energy for 50 weeks each year, fve days a
week, and eight hours a day. Te rotary motor will cost $315
per year per axis to run. Switch the rotary motor for a linear
motor and cost is reduced to $200 per year per axis sig-
nifcant savings for machines having hundreds of axes.
Scalable Offerings
Mechatronic design software also can help engineers save
time and money by properly sizing control equipment,
because over- or under-sized components can add unnec-
essary expense. Implementing scalable, right-sized control
systems can help OEMs meet a variety of end-user needs
in a cost-efective, design-efcient manner.
Scalable oferings are designed to meet a variety of
application needs while providing a platform that can
operate on all machines, from complex to simple. Scal-
ability helps reduce total cost of ownership by enabling
OEMs to use a single design environment across a range
of machines. Tey also can reuse code, human-machine
interface (HMI) faceplates and design best practices from
system to system. Tis saves time during design, develop-
ment, commissioning and maintenance after the sale.
For example, JANDA Company Inc., an OEM that
specializes in manufacturing resistance welders, realized
several benefts from implementing a scalable solution based
on the Logix control platform from Rockwell Automation.
Te company reduced both design and commissioning
time by 25%, improved installation time by 30%, improved
tolerances from 1/8 in. to 0.0001 in. reduced control panel
size by 50% and reduced overall maintenance time through
the implementation of scalable automation.
JANDA can match the control requirements of each
end user through the use of scalable solutions that
provide more efciency and sustainability. Te end user
benefts through reduced waste and energy and main-
tenance costs. Tey also can scale the automation up
to meet growth needs in the future, without having to
retrain workers or recode equipment.
Designing a Better,
More Sustainable Machine
Used collectively, mechatronic design tools and scalable
automation helps enable OEMs to design and deliver
more efcient, sustainable machines.
Motion Analyzer is available as a free download at
http://ab.rockwellautomation.com/motion-control/motion-
analyzer-software.
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>>
Inverters, drives, variable-frequency drives
(VFDs) or motor drives whatever you call
them, engineers understand and accept their perfor-
mance-enhancing, energy-saving and motor-protection
benefits. That acceptance has led to a proliferation of
drives offerings, with much of the hardware based on
similar technology delivering excellent quality across
leading brands. Engineers considering drives options
might want to focus on the ease-of-use tools and features
provided by the configuration software as much as the
actual hardware. By examining the whole drives pack-
age, especially the configuration software, engineers can
make a more informed decision that saves them time and
labor during configuration, commissioning and start-up.
Drives confguration software is experiencing rapid
evolution, making it more powerful and easier to use.
Te most profound advancements involve integrating the
controller and drive. For networked drives, integration
capabilities help lower programming, installation and
overall ownership costs by minimizing the software tools
required. Tis helps users gain faster start-ups, improved
accuracy and easier drive-system maintenance.
Traditionally, adding a drive to a control system
meant learning to work with a new software tool and
managing separate drive confguration fles. By using
programming software that integrates the drives and
the controller, users have a shorter learning curve and
can manage the drive and the control system more
easily because there is only one software package to
purchase and learn. With integrated drive confguration
software, users can reduce the chance of mismatched
I/O, streamline data, remove cryptic parameters and
simplify coding.
Reduce Mismatched I/Os
When installing drives, a major complexity is confgur-
ing the settings to sync up between two programming
environments. For example, a confict in the I/O con-
fguration setting can arise when the controller and drive
are confgured at diferent times with diferent tools.
In other words, the controller expects one size of I/O
while the drive is confgured for a diferent size. Tis
mismatch creates an I/O connection error in the program
and can become a nuisance for programmers, typically
during system start-up when time can be limited.
In the past, the frst phone call to tech support
involved troubleshooting to remedy these communica-
tion gaps. With integrated drives confguration, users
now can confgure both sides of the network connection
at the same time with one tool, reducing the potential
for errors. Tis capability can be especially benefcial in
applications involving a large number of drives, where
managing the various confgurations can consume an
inordinate amount of engineering time and resources.
Streamline Drives Conguration Data
To ease maintenance and improve access to information,
some software saves drive confguration data as part of
TAKE THE PAIN OUT OF
DRIVE SYSTEM DESIGN AND START-UP
Drives conguration software that focuses on ease-of-use tools can enhance motor-drive
installation and save time and labor during conguration, commissioning and setup.
By Greg Mears, Product Manager, Drives Software, Rockwell Automation
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the controllers project fle and also stores it in the con-
troller. As a result, theres no need to store and maintain
multiple fles users only need one fle for both the
controller and all drive confgurations.
In the event of a failure, replacing and restoring the
original drive confguration is a much easier process. In
some cases, the controller can download the confgura-
tion to a replacement drive automatically, further reduc-
ing down-time.
Remove Cryptic Parameter Descriptors
Users can face a major challenge when individually
programming parameters and tags when configur-
ing drives. Many controllers store drive informa-
tion in memory as a contiguous block, where each
drive parameter is represented by a physical address
or number rather than a descriptive name. Typical
tags might read .data3 or .data4, forcing users to
constantly refer back to user manuals to interpret and
document the control program. This tedious task is
time-consuming and often must be repeated for each
drive in a system.
Engineers installing drives should look for program-
ming software in which a device-specifc data structure is
created automatically. Tese data structures now can be
represented with descriptive names rather than generic
numeric-based, parameter-addressing schemes used in
the past. Te data structures also use the proper data
types integer, real, Boolean, etc. for each param-
eter, so no manual data-type conversion is required by
the programmer.
Engineers also should seek software options that
provide network I/O drop-down boxes containing all
the parameter names. Tis minimizes the potential for
errors when defning various network I/O. Tags can then
be created in the control development environment and
accessed via a human-machine interface (HMI), reduc-
ing set-up and confguration time. A copy-and-paste
programming feature can create additional duplicate
drives quickly.
>> Free: Webinar: EPLAN/RSLogix - Closing the Gap Between Hardware & Software Design
In this free 1-hour webinar, learn how to share engineering data between departments
within your organization, resulting in one set of consistent data. See how EPLANs cen-
tral database interfaces with other software programs such as RSLogix
TM
5000, RSLogix
Architect and Integrated Architecture Builder (IAB). Demos will include bidirectional
synchronization of controls hardware and tag synchronization and how to incorporate
Rockwell Automation-certified product data into electrical designs via the EPLAN Data
Portal with just a drag-and-drop into your schematic.
Watch this Free Webinar from Rockwell Automation Encompass
TM
Product Partner
EPLAN Software & Service.
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Simplify Coding
A common problem in many drives installation
projects is that multiple engineers develop differ-
ent versions of the same code. With numerous code
variations, installation and start-up become more
tedious and complex. Thats because engineers must
check and verify each version and the specific set
of errors used with each code to confirm a smooth
installation.
Programming software capabilities, such as user-
defined add-on instruction, encapsulate drive-specific
operations into a reusable module of code. This
reduces the development and validation effort, and
promotes consistency among projects because theres
no need to constantly reinvent commonly used con-
trol algorithms.
Some software packages further simplify the
programming of networked drives with tag genera-
tor tools. Users no longer have to worry about I/O
mapping and correlating the I/O image with device
user manuals. Tag generating tools help save users a
significant amount of programming time per device,
depending on the devices complexity.
Start-up wizards for drive commissioning are
another key advancement. Instead of using a linear
list editor to navigate through hundreds of param-
eters, startup wizards provide a simple step-by-step
process. Graphs, images and descriptive text assist the
user through the remaining commissioning process.
Besides dramatically reducing drive startup and com-
missioning time, wizards can improve set-up accuracy
by significantly reducing manual configuration with
the end device.
Engineers can also enjoy the benefits that device
configuration software can offer to simple, hardwired
or stand-alone applications. Drives are just one of
many components in a system. For these applications,
device configuration software can take what once re-
quired several different software configuration tools,
and wrap it into a single software package with a
simple catalogue of devices available at the engineers
fingertips.
Make it Painless
Combining a controller with a full suite of compati-
ble components and application development tools
application profile, quick starts, wiring diagrams and
predeveloped HMI screens can provide engineers
with a simplified way to implement common control
tasks as part of the machine design. This improves
user experience and reduces the risk of potential
engineering programming, training and maintenance
nightmares.
Clearly, its not just about the hardware anymore.
With simplified programming software, engineers
can say goodbye to the complicated world of drive-
controller integration and hours of grueling tagging
and coding validation. Advancements in program-
ming software capabilities are just the start of inte-
gration and interconnectivity capabilities to come.
Rockwell Automation Integrated
Conguration Tools
www.rockwellautomation.com/go/iatools

DeviceLogix-Enabled Products for
Drives Conguration
www.rockwellautomation.com/go/devicelogix
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>>
To employees, all safety is personal es-
pecially electrical safety. Little else matters
unless electrically safe work conditions can be created
and maintained throughout their work environment.
Article 120.1 of the NFPA 70E establishes the procedure
for creating an electrically safe work condition. Use of
permanent electrical safety devices (PESD) in lockout/
tagout (LOTO) procedures has increased, primarily
because PESDs improve the workers abilities to isolate
electrical energy safely.
Since article 120.1 of the NFPA 70E was penned,
innovation in electrical safety has surpassed the precise
language of Article 120.1(1-6) because the standard
doesnt speak directly to how PESDs can improve a
workers ability to isolate electrical energy safely beyond
that which was originally conceived when Article 120
was written. However, PESDs still adhere to the core
principles found in Article 120.1. (Learn more by down-
loading Grace Engineered Products free white paper at
http://goo.gl/o0MTs2.)
With PESDs incorporated into safety procedures (see
Figure 1), installed into electrical enclosures correctly
and validated before and after each use, workers can
make verifying voltage into a less precarious undertaking
that doesnt expose them to voltage.
Validating a Voltage Detector
Creating an electrically safe work condition depends
upon a process that ensures 100% accuracy from voltage
detectors. Te NFPA 70E 120.1(5) says, Before and after
each test, determine that the voltage detector is operating
satisfactorily.
HOW TO IMPROVE LOTO SAFETY
Learn how permanent electrical safety devices help protect workers from arc ash
and other hazards in accordance with NFPA 70E and OSHA requirements.
By Philip B. Allen, Grace Engineered Products, Inc.
Figure 1. This is an example of installation of a voltages indicator and
voltage portals on a typical three-phase panel.
t
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20 20
Validation means that electricians frst check their
voltage detector to an independent voltage source, such
as a nearby 120VAC outlet. Next, they check for zero
voltage on the primary source. Work begins only after
the voltage detector is rechecked to the independent live
voltage source.
Tis validation procedure works for a portable voltage
detector because workers can move it physically between
two voltage sources. However, because a PESD cant be
moved between two voltage sources, the technique for
validation needs a slightly diferent approach.
So what actually needs to happen to validate a volt-
age detector? Testing for voltage simply requires a small
amount of current to fow between the two voltage po-
tentials. Te voltage detector circuit determines a voltage
potential by relating this current fow to actual voltage
and providing the worker an appropriate indication
(audible, visual or digital display).
Validating a Voltage Portal & Noncontact
Voltage Detector Combination
A noncontact voltage detector (NCVD) determines if
voltage exists in a conductor by creating a low current
capacitive circuit between the conductor, the NCVD,
the worker and ground (see Figure 2).
Terefore, when the NCVD is positioned close to a
live conductor, this completed circuit causes the NCVD
to beep or fash, telling the worker that voltage exists in
the conductor. Because voltage portals mount perma-
nently to the outside of enclosures, the worker has to
stand in the same place when using his NCVD. Tis
makes this capacitive circuit more reliable and more
repeatable than it would be when workers use a NCVD
in all other applications.
Because NCVDs are portable, they also can be
checked to an independent voltage source as per NFPA
70E 120.1(5).
Minimum Requirement for
a Voltage Indicator
A voltage indicator is hardwired to the three-phase discon-
nect and earth ground (see Figure 3). Te circuit illumi-
nates LEDs when AC/DC voltage exists between any two
Figure 2. Proper voltage portal installation improves reliability of
noncontact voltage detector (NCVD) operation.
t
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21 21
phase(s) and ground. Since voltages above 50V are deemed
unsafe by NFPA 70E, its imperative that the LEDs on a
voltage indicator illuminate for all voltages above 50V.
Validating a Voltage Indicator
A hardwired voltage indicator brings up three interesting
issues. First, its impractical to verify the voltage indica-
tor to another independent voltage source. Trying to
accomplish this by adding a switch to toggle between the
line voltage and the test voltage adds more components
and complexity, which can lead to unreliability.
Second, because the voltage indicators sole purpose is
to indicate voltage, anything installed between the source
voltage and the voltage indicator such as switches,
relays and fuses increases the chance of a false-negative
voltage reading.
Tird, because of the three-phase circuit design, a
voltage indicator accommodates multiple current paths
between phase(s) and ground, thereby reducing the
number of possible failure modes. In one possible circuit
design, before a single LED illuminates, the current
must pass through at least four LED-fashing circuits.
Voltage when illuminated means if only one of the
four LEDs illuminates, it still provides voltage indication
to the worker.
>> VIDEO: Infrared Inspection Technology Helps Protect Workers from Electrical Hhazards
In this video from the 2013 Automation Fair
event, Phil Allen from Grace Engi-

neered Products Inc. demonstrates its new line of infrared inspection windows using
patented Polymer-based technology that maintains its characteristics the entire
lifetime of the window. Grace also exhibits a new offering to its Permanent Electri-
cal Safety Devices (PESDs), a fiber-optic voltage indicator that mounts inside the
electrical panel and transmits voltage indication signals to outside the panel to the
fiber-optic bundle so theres no voltage on the outside of the panel.
Watch the video now!
Figure 3. A voltage indicator is hardwired to the three-phase discon-
nect and earth ground. The circuit illuminates LEDs when AC/DC volt-
age exists between any two phase(s) and ground.
t
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Multimeters Compared to PESDs
Until PESDs came along, creating electrically safe work
conditions relied solely upon the portable multimeter.
Verifying the proper operation of a multimeter and
testing for absence of voltage before working on electri-
cal conductors still must remain a habitual practice for
workers. PESDs ensure when workers test-before-touch,
they test only dead conductors.
Te traditional method of validating the voltage
detector to an independent voltage source is met with the
NCVD-voltage portal combination. On the other hand,
it can be argued that a voltage indicator by itself cant be
validated by the traditional method.
However, because permanently mounted voltage de-
tectors are designed only to detect voltage, users should
consider its advantages compared to a multimeter when
validating this device (see Figure 4).
A PESD becomes a real safety device only after it is
included as part of a written LOTO procedure. Without
this, PESDs are nothing more than just another electri-
cal component. Te LOTO procedure must explain
to the worker each step in the LOTO procedure that
involves the PESD. At a minimum, employees will need
to verify proper operation of the PESD before and after
performing a LOTO procedure.
Rigid Yet Flexible
Safety is an evolution based on best work practices and
innovation. High safety standards create safer workplac-
es and encourage safety innovations. Safety standards
must be rigid enough to garner the highest level of safety
while still being fexible enough to allow advances to be
incorporated.
Download Grace Engineered Products free white paper
about lockout/tagout safety and permanent electrical safety
devices at http://goo.gl/o0MTs2.
Grace Engineered Products, Inc., Davenport, Iowa,
is a participating Encompass
TM
Product Partner in the
Rockwell Automation PartnerNetwork
TM
. The company
manufactures connection/cable interfaces, NEMA-rated
convenience communicators and other electrical safety
devices.
Grace Engineered Products, Inc.
www.rockwellautomation.com/go/p-grace
Rockwell Automation Encompass Partner Program
www.rockwellautomation.com/go/tjencompass
Figure 4. The sole function of permanently mounted voltage detectors
is to detect voltage.
t
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23 23
Simply open the Newsstand on your iPad, tap the Store,
and search ROKJournal to download the Te Journals
free iPad app.
Te app delivers each issue of the magazine plus features
that only a tablet app can ofer, such as:
Product demonstrations
Video interviews
Downloads
Links to websites
Social media sharing
Te Journals iPad app makes your user experience
interactive, fun and useful!
Download
The Journals
New iPad App!
Search ROKJournal in
your iPads Newsstand Store
and download The Journals
free iPad app today!
t
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>>
When a fertilizer manufacturer planned to
upgrade its plant to use high-horsepower
variable-frequency drives (VFD), it needed a new cable
solution to go with it. The companys existing armored-
type cables were deteriorating quickly because of the
plants harsh environment that included salts, chloride
and potash.
Te cables experienced connectivity loss that caused
unscheduled downtime. Codale Electric Supply, Inc., West
Valley City, Utah, implemented a new cable solution for
the VFD upgrade that uses insulated gate bipolar transis-
tor (IGBT) technology to reduce unplanned downtime.
Te fertilizer plant upgrade involved converting Allen-
Bradley PowerFlex drives to the new PowerFlex 755 AC
drive with predictive diagnostics. Predictive diagnostics
allows the manufacturers personnel to program the
PowerFlex 755 drive to monitor the run-time hours for
machine bearings or motor bearings. It also provides ad-
vanced notifcation to help prevent unplanned downtime
that afected the bottom line.
Selecting the Right Cable
for the Application
Andy Hedrick, industrial accounts manager and Brett
Payne, product manager/Allen-Bradley drive specialist at
Codale, an Authorized Allen-Bradley Distributor, recom-
mended the ServiceDrive ASD/VFD cable system (see
Figure 1) Service Wire Co., an Encompass
TM
Product
Partner in the Rockwell Automation PartnerNetwork.
Tey believed this cable system would help when used as the
connection method between the new VFD and the motor.
HARVEST THE CORRECT CURRENT
Discover how a fertilizer manufacturer uses insulated gate bipolar transistor
technology to solve variable-frequency drive cable problems.
Figure 1. The fertilizer manufacturer installed a new cable system with
Insulated Gate Bipolar Transistor technology for use with its new Pow-
erFlex 755 AC drive. The cable system provides a low impedance path
between the drive and motor assembly and helps reduce unscheduled
downtime caused by connection failures.
t
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25 25
Te system consists of cables of symmetrical construc-
tion with three conductor and three ground, 5-mil-thick
copper tape shield, with matching connectors. Te cop-
per tape shield is helically applied, and has 50% overlap
for integrity. Tis design provides a low impedance path
between the drive and motor assembly.
Hedrick and Payne also believed the new cable system
would help the fertilizer manufacturer decrease unsched-
uled shutdowns (see Figure 2).
Te manufacturer believed that using the ServiceDrive
cable with its matching connector and termination kit was
superior to any other standard cable available, Payne says.
Using the complete ServiceDrive cable system gave them
more confdence with the impending VFD installation, lead
length and control over motor issues. In fact, the frst up-
grade garnered such strong benefts that the fertilizer manu-
facturer has used the VFD cable system for all upgrades with
the Rockwell Automation solution.
Faster Output Voltage
Te IGBT technology on the new cable system enables
device rise-and-fall time switching capability fve to 10
times faster. Tis helps to reduce device-switching loss
and creates a more efcient drive.
For the drives, the faster output-voltage rise time
might increase the dielectric voltage stress on the motor
and cable because of a phenomenon called refected
wave. Most AC drives, in addition to their normal three-
phase output voltages, create a fourth unintended voltage
to ground, known as Common Mode Voltage (CMV).
CMV is current that leaves a source and doesnt return to
the source. In most closed-loop electronic circuits, most
of the current returns to the source.
However, a small amount of current in any circuit is
radiated and doesnt return. Minimizing this efect means
controlling any noise that might enter a system, because
its detrimental to equipment and information integrity.
Generally, people assume that ground is ground, and
no matter where you attach it, theres no diference.
However, grounds arent all the same. Even at diferent
points on the same ground wire, diferent possibilities
exist for noise to enter because of resistance and radia-
tion. If not fltered out, large motors and power devices
can generate pulses (EMI) and line voltage spikes that
interfere with more sensitive electronic devices. Combin-
ing the two can amplify the problem.
The Right Cable Matters
When a VFD goes down, everyone is under pressure to
get it back online. If a cable failure causes the shutdown,
it might take even longer to fnd and resolve the prob-
lem. Selecting the right cable solution for the VFD can
help maximize productivity and proftability.
Service Wire
www.rockwellautomation.com/go/p-servicewire
Allen-Bradley PowerFlex Drives
www.rockwellautomation.com/go/tjpowerex
Figure 2. The synergy created between the new cable system and the
VFD drive helped the fertilizer manufacturers drive/cable-motor assem-
bly to provide superior performance.
t
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26 26
V I oltage ndicators
NO VOLTAGE
at the door!
SafeSideR-3FfromGrace Engineered Products uses an
optical light cable (with lengths available from12 to 72) to
transmit LED voltage indication up to a thru-panel adaptor
on the outside of electrical enclosures. This design allows
workers to stay on the safe side of electrical panels with a
no-voltage-at-the-door option.
R-3F Features
Other Benefits:
?
?
?
?
?
20-600 VAC*/ 20-1000VDC
CAT III/IV Electrical Rating
UL Type 4X, 12, 13
Optical Cable lengths up to 72
Potted Construction with 6 Lead
Simplifies PPE
Stored Energy Detector
Visible Blades Disconnect
Permanent Device
Voltage Source Labels
*
(pending)
?
?
?
?
?
(non-UL max 750VAC)
800.280.9517 www.pesd.com
INTRODUCING
H
ey, Les, look! N
o voltage is at the door!
t
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