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CoTMD09
Integrated Architecture Builder:
Build and select the right
architecture

CHANNEL ON THE MOVE

2014 Training

For Classroom Use Only!

Important User Information

This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation)
is intended for use only as a learning aid when using Rockwell Automation approved demonstration
hardware, software and firmware. The Documentation should only be used as a learning tool by
qualified professionals.
The variety of uses for the hardware, software and firmware (hereinafter Products) described in this
Documentation, mandates that those responsible for the application and use of those Products must
satisfy themselves that all necessary steps have been taken to ensure that each application and
actual use meets all performance and safety requirements, including any applicable laws, regulations,
codes and standards in addition to any applicable technical documents.
In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter
Rockwell Automation) be responsible or liable for any indirect or consequential damages resulting
from the use or application of the Products described in this Documentation. Rockwell Automation
does not assume responsibility or liability for damages of any kind based on the alleged use of, or
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equipment, or software described in the Documentation.
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properly using, calibrating, operating, monitoring and maintaining all Products consistent with
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and
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Identifies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
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Identifies information that is critical for successful application and understanding of

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Identifies information about practices or circumstances that can lead to personal

injury or death, property damage, or economic loss. Attentions help you:
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avoid a hazard
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Integrated Architecture Builder: Build and select the right

architecture
Contents
BEFORE YOU BEGIN_________________________________________________ 5
About this lab ____________________________________________________________ 5
Topics covered ___________________________________________________________ 5
Software _________________________________________________________________ 5
Lab files _________________________________________________________________ 5

DOCUMENT CONVENTIONS ____________________________________________ 6

INTRODUCTION TO THE LAB ___________________________________________ 7
CREATE A CONNECTED COMPONENTS ARCHITECTURE USING A WIZARD ___________ 8
Adding the Ethernet network ______________________________________________ 15
Adding the Motion Drive __________________________________________________ 18
Adding the Operator Panel ________________________________________________ 19
Adding the Standard Drive ________________________________________________ 20
Selecting Ethernet cables _________________________________________________ 22
Using the Architecture View _______________________________________________ 23
Creating a report _________________________________________________________ 24
View the Bill Of Material (BOM) ____________________________________________ 26

CREATE AN INTEGRATED ARCHITECTURE USING THE ADD NEW HARDWARE OPTION _ 29

Adding controller hardware ________________________________________________ 30
Adding the Device Level Ring Ethernet/IP ___________________________________ 33
Adding the Remote I/O Modules ___________________________________________ 35
Adding the HMI PanelView Plus ___________________________________________ 41
Adding the Standard Drive and Motion Drives ________________________________ 43
Checking the Network Performance ________________________________________ 47
Performing a general check _______________________________________________ 50
Adding Infrastructure 4 Architecture using the Wizard. ________________________ 53
View the Bill of Material ___________________________________________________ 77
Sharing the BOM with ProposalWorks (ONLY READ THROUGH) ______________ 78

COMPARISON BETWEEN MIDRANGE AND CONNECTED COMPONENTS SOLUTIONS ____ 81

Controllers Comparison ___________________________________________________ 85
Human Machine Interface (HMI) or Operator Panels Comparison_______________ 87

Motion Servo Drives Comparison __________________________________________ 89

Networks topologies and protocols Comparison ______________________________ 91
Standard Drives Comparison ______________________________________________ 92

APPENDIX A: QUICK SELECTION REFERENCE _____________________________ 94

APPENDIX B: CIP CONNECTIONS QUICK REFERENCE ______________________ 101
APPENDIX C: DEVICE LEVEL RING QUICK REFERENCE _____________________ 105
APPENDIX D: IA-VERTICAL FORM, FILL AND SEAL (VFFS) MACHINES___________107
APPENDIX E: CC-VERTICAL FORM, FILL AND SEAL (VFFS) MACHINES__________112
APPENDIX F: PLCOPEN MOTION CONTROL EXAMPLE______________________127
APPENDIX G: PTO MOTION CONTROL EXPLAINED_________________________132

Before you begin

This lab is intended to give you an opportunity to understand how to leverage the tools provided by Rockwell
Automation and increase your productivity.

About this lab

This hands-on lab starts with the basic stapes to create two different architectures, so anyone, even with no
experience, can learn how to use the Integrated Architecture Builder. Then we give some tips and suggestions
on how to compare the two solutions in order to find out which is best for you and your application.

Topics covered
In this lab you will:

Create a Connected Component Architecture and an Integrated Architecture.

Compare the two solutions.

Software
This Hands-On Lab uses the following software:

Microsoft Windows 7 SP1

Integrated Architecture Builder v9.5

Lab files
No initial Lab files needed

Document conventions
Throughout this workbook, we have used the following conventions to help guide you through the lab materials.
This style or symbol:

Indicates:

Words shown in bold italics (e.g.,

RSLogix 5000 or OK)

Any item or button that you must click on, or a menu

name from which you must choose an option or
command. This will be an actual name of an item that
you see on your screen or in an example.

Words shown in bold italics,

enclosed in single quotes (e.g.,
'Controller1')

An item that you must type in the specified field. This is

information that you must supply based on your
application (e.g., a variable).
Note: When you type the text in the field, remember that
you do not need to type the quotes; simply type the words
that are contained within them (e.g., Controller1).
The text that appears inside of this gray box is
supplemental information regarding the lab materials, but
not information that is required reading in order for you to
complete the lab exercises. The text that follows this
symbol may provide you with helpful hints that can make
it easier for you to use this product. Most often, authors
use this Tip Text style for important information they
want their students to see.

Note: If the mouse button is not specified in the text, you should click on the left mouse button.

________________________________________________________________________________

Introduction to the Lab

Rockwell Automation offers solutions to all needs and in the medium size and small size applications the
portfolio has improved year on year with new and extended capabilities. In order to make sure our customers
always find the right solution we have developed from two directions what is called the Connected Components
and the Integrated Architecture families of products.
The first solution providing just enough control to meet the needs of machine builders under pressure to meet
stringent cost objectives. The second solution providing an all-round technology with practically no or little
limitations in terms of applications.
To be able to appreciate the differences and the advantages of both architectures, we will use our key tool to
design and evaluate automation solutions, this is called: Integrated Architecture Builder (IAB).
NOTE: even though the name may be misleading, the tool is now including: Micro800, Process, Software,
Migration and other solutions beyond IA.
There are two different ways to create an architecture in IAB:
1. a Wizard: when starting from scratch and need a step by step procedure to help you. This would be
better suited when there is only a machine drawing and a list of I/Os.
2. or the Add New Hardware: use this method for manual configurations. . This would be better suited if
you already have a close to final list of automation hardware to start with. Or you have already
experience with the tools and would like to skip the steps you dont need.

________________________________________________________________________________

Create a Connected Components Architecture using a Wizard

As already mentioned IAB includes wizards to help create architectures based on specific controllers or needs.
These include: ControlLogix, CompactLogix, Micro800, Distributed I/O, PlantPAx Estimator, 1771
Migration, SLC Migration, DIO Migration. In this section we will show how to use the Micro800 wizard.
To begin we will create a new project.
1. Find and double-click on the Integrated Architecture Builder icon to launch IAB.

If asked to establish an Internet connection, click No:

The IAB start page appears, with IAB Project Options displayed:

Click New Project.

The Create a New Workspace dialog appears:

2 In the Create a New Workspace dialog, select Blank and type in the Workspace Name
then click OK. IAB opens a new workspace.

CC_Arch,

Suppose you have decided to use a Micro850 as the controller for your application with the following
requirements:

Local I/O :
o 20 DC inputs,
o 15 DC outputs,
o 12 analog inputs,
o 4 analog outputs

2 axes of motion control (Kinetix300)

1 Operator Panel (PanelView component 600)

1 Standard drive (PowerFlex 525)

Ethernet as the main network (Stratix2000)

IAB opens the new workspace on the left window pane and shows the project name as CC_Arch

1. If not shown yet, check on the bottom left, under the Workspace window and click on the Wizard View
to start with this part of the lab.

2. Click on the Micro800 icon on top of the bar to launch the wizard.

3. The first page is called Subsystem Preferences. Selections on this page are for information only to give
an overview on the different platforms available. They give family overviews and a link to the selection
guides. Try the radio buttons yourself.

Note: all three PDF links refer to the Micro800 Programmable Controller Family Bulletin 2080 Selection
Guide (2080-sg001)
4. Leave the radio button unchecked click Next to go to the next wizard page.
The Communication & Controller options page will open. This step lets you specify your communication
requirements and certain optional controller features. Notice the green checkmarks on the right side of the page.

NOTE: A green checkmark indicates that the controller can handle all the requirements you have specified in the
wizard. Since no selections have been made yet, Micro810, Micro830 and Micro850 are available. A red X
indicates that the controller cannot handle the specified requirements.
5. As you may notice we follow the wizard from top to bottom. Now we can choose the Communication &
Controller Options.
In our architecture we need the Ethernet/IP network. Click the Ethernet/IP checkbox. The Micro810 and
Micro830 controllers are then excluded (see the red X), since there is no Ethernet/IP port available.
From now on only the Micro850 will be used.

Click Next to go to the next wizard page.

6. The Motion Options page lets you select the specific type of axis for you application.
Read the asterisked note in the Embedded Options section. This note tells you that selections you make
here will affect the number of I/O you can specify on subsequent pages.

Set Embedded 100kHz PTO Motion Axes (24v DC) to 2 and click Next.

NOTE: The Micro850 can support 3 PTO motion axes maximum.

7. Now we can set the Digital I/O requirements. We will need 20 DC Inputs 24V AC/DC, and 15
Source 24V DC Outputs. When done click Next.

8. On the Analog I/O page, enter 12 Voltage Analog Inputs and 4 Analog Outputs, and click Next.

On the last step of this wizard IAB displays the Hardware Selection page. On this page, you have the full
summary of your architecture and the option to select among different controllers and include the power supply.
Please, select the Include 120V/240V AC Power Supply check box.

Notice, in our case the only option in the drop-box supporting the requirements is the Micro850 family. Then,
within the Micro850 family you can select a specific controller whenever available.

The table shows also the I/O points provided by the controller, the plug-ins modules and the expansion I/O
modules to meet the specified requirements.

The bottom left of the display shows the numbers of plug-in slots and expansion IO available and the number of
plug-ins and expansion IO modules selected.

This last step allows for any change or addition you feel is necessary to meet the requirements. Notice the
specialty modules are also available in this window
9. Click Finish to complete the configuration.

10. Click the Hardware tab on the bottom left to view the completed Micro850 controller.

Adding the Ethernet network

Next, we will connect the Micro850 controller to an Ethernet/IP network using Stratix2000 switch.
11. Right click on the controller chassis and notice the network connections that you can make. On this
Micro850 controller, connections for EtherNet/IP, Serial ASCII, and Modbus Serial are available.
Select Connect to Ethernet/IP Network > Connect EtherNet to a new EtherNet/IP network >
Standalone Switch.

Accept the default name for the new EtherNet/IP network. IAB connects the controller to a new EtherNet network.
Click the Network tab on the bottom left to see the network view.

Now, select the Switch001 tab. Next, we will change the Stratix5700 switch created by default with a Stratix2000
switch 5 ports.
12. Right-click on the Stratix5700 switch and select Switch Properties.

13. The Ethernet Switch Properties dialog appears. Select 1783-US5T switch in the catalog # by using the
down arrow and click OK. Notice the catalog number means Unmanaged Switch 05 ports Twisted pair
(copper)

Click OK.
The Stratix2000 5 ports switch appears in the network.

Adding the Motion Drive

Next, we will add 2 x Kinetix 300 Servo Drives to the network in order to control 2 axis.
14. At the bottom of IAB there is now available all devices you can connect to the network. In the device list
open Network Devices>Motion Control. Expand the Servo Drives folder, then Kinetix 300 folder, find
the 2097-V32PR0 servo drive. Hold down the Control key (Ctrl) and drag a 2097-V32PR0 to the
network.
15. In the Add Multiple Devices dialog that appears, enter the number 2 and click OK:

IAB adds two K300 servo drives to the Ethernet network:

Adding the Operator Panel

Next, we will add a PanelView Component PVc600 to the network to allow the End User full access to the
machine.
16. In the device list at the bottom of IAB you can either type in the search box the catalog number youre
looking or expand the folders Computers and Operator Interface>Graphic Terminals>2711C
PanelView Component>PanelView Component C600 and drag and drop anywhere one 2711C-T6T
to the network:

IAB adds the new PanelView Component C600 to the Switch001 network.

Adding the Standard Drive

At last, we will add the PowerFlex 525 drive to the network Cat. Num. 25B-A2P5N104.
17. Enter 25B in the search box and click Search. You will be shown three types of drives and since we
want to be cost effective and need only one Ethernet port we will select the first in the list 25B***:
PowerFlex525 Drive Ethernet/IP.

Drag and drop to the Network view.

Choosing the PowerFlex525 will launch the RAISE Product Configurator Assistant, just like ProposalWorks. In
fact all selection tools share the same exact database.
18. In the Raise Product Configurator select the following:

19. Make sure the Catalog Number is 25B-A2P5N104 then click Accept when complete.

Click Network View > Switch 001, you will see the following architecture.

You have built the Connected Components architecture in an Ethernet network using a Stratix2000 Switch.
Before continuing, save your work by clicking the Save button on the top IAB tool bar.

Selecting Ethernet cables

The best and easiest way to modify the Ethernet cables is to open the Network View select the Switch001 Tab
and find on the top bar the Configure Cabling

20. As you open the new configuration window you will have full access to all cable options.
The first and most important step is to choose the cable type, which can also be Customer Supplied Coper
Cable

Then on each port you can select a different cable in terms of jacket, gauge, color, # of conductors and length
(see next picture).

Click OK when finished.

Using the Architecture View

The Architecture View is a bird eye view of all devices and networks created, in order to help the designer
check and be sure the solution is complete. It will also allow customize the position of the devices, add new
devices, add areas with labels and print a report with the full architecture drawing.
21. Select Architecture View at the bottom left of the project page

Notice, the Workspace now shows all devices and the new tab shows the full architecture similarly to the Network
view. While in the Network view the is no way to move around objects in this new view you can play as you need.

22. Try moving the objects, select Add Area and play with areas or see the example below.

Creating a report
Lets try the reporting capabilities of IAB and click on the MSWord icon on the top right menu bar

When prompted click Yes on the next popup window

23. The system may detect automatically issues in your project. This is obviously a great help in minimizing
the mistakes as you go on with your project. For the purpose of this Lab we will for the moment ignore
the warnings and select Yes

24. Save in the default location and then take your time to read and understand the next important note:

25. Click OK and click Yes to open the report as described in the next window:

26. Accept to link fields to other files by selecting Yes:

27. As the report opens in MSWord scroll through the document and find out it is a very powerful and
detailed list of all the benefits of our solutions down to any warning, error, BOM (three versions)

View the Bill Of Material (BOM)

IMPORTANT: during installation, the user specifies a country location, which determines which price list is used.
This becomes the System Provided List Pricing which is updated through the Current Program Updater. This
is also the default setting where IAB uses RAISE list price data to fill descriptions and prices in the BOM.
28. On the toolbar click the Project BOM button:

29. The full Project BOM for the project appears. All parts in the project are listed, along with pricing
information.

Notice the product descriptions and prices. (Descriptions and prices in your BOM display may differ from those
shown here, depending on the price file(s) you have installed)
30. On the top bar select Option then IAB Options. This will allow you to change your settings and decide
which price list to use

31. As may notice the default setting is to use the online list called System Provided List Pricing, but
you can also chose the User Provided Pricing . In case youre using the pricelist from our RAIN,

REMEMBER to check the box next to Ignore dash (-) in catalog number.

32. In case you would like to use a special or personal price list, all you need is a csv file with at least three
columns: Catalog number, Description and Price. To see how it works select the button Add

33. Click on the folder icon then search for the IAB Lab Demo Price File.csv file as an example
C:\Program Files (x86)\PST\RA_IAB\Labs\ IAB Lab Demo Price File.csv
34. Once selected the file click on Get From File and chose column 5 for the Catalog

then repeat for the Description (#7) and the Price (#10). Click OK on all windows and go back to IAB.
Note: when IAB generates a Bill of Materials, it looks to price files that you supply to find descriptions and
prices for items in the configuration. You can specify one or more price file files that IAB will search. IAB
searches the price files in the order they are listed and uses the first instance it finds of a catalog number to
provide the descriptions and price for the BOM. Use the up/down arrow buttons to prioritize the order in
which the files are searched.
35. Now run again the Project BOM and compare with previous prices list (see p. 26).
36. Close the BOM window and save your work by clicking the Save button on the IAB tool bar.

This completes the IAB Connected Components lab exercise

___________________________________________________________________________________

Create an Integrated Architecture using the Add New Hardware option

Now that you are more familiar with the tool, lets create a second architecture where the core technology is now
the so called IA. This is made of controllers in the Logix family and includes PanelView Plus, Kinetix, Stratix,
PowerFlex
1. If IAB is already running, click the New button and move to point 3. If not, follow the next steps.

2. Find and double-click on the Integrated Architecture Builder icon to launch IAB.

If asked to establish an Internet connection, click No:

The IAB start page appears, with IAB Project Options displayed. Click New Project.

3. The Create a New Workspace dialog appears:

4. In the Create a New Workspace dialog, select Blank and type in the Workspace Name
Midrange_Arch, then click OK. IAB opens a new workspace.

Adding controller hardware

This time we will use the Add New Hardware method to build a Midrange Architecture.
For the purpose of the Lab we will consider the case where we have a list of hardware:
CompactLogix5370 L1x.
Distributed Point I/O.
PanelView Plus 600
ETAP (to add non Device Level Ring devices to a ring or linear topology)
PowerFlex 525
2 x Kinetix 5500 Servo Drives (2 integrated motion axes)
5. Click the New Hardware button. IAB displays the Add New Hardware dialog:

6. Under CompactLogix, select CompactLogix5370 L1:

Click OK to continue.
IAB creates an empty CompactLogix5370 L1 chassis with slots for Point I/O expansion modules:

At the bottom, in the CompactLogix device list, expand the Controllers folder and then the 5370 L1
Controllers (w/Point I/O) folder. Check the descriptions of the three L1x processors listed there:

Only the 1769-L18ERM-BB1B from L1x processors family can control 2 CIP motion axes and meet the
requirements.

7. Select the 1769-L18ERM-BB1B and drag it into the slot at the left end of the chassis (to the left of slot
1).

IAB creates the 5370 L1x chassis. The 1769-L18ERM-BB1B controller has 16 embedded DC
Inputs and 16 embedded DC outputs. We will not add additional POINT I/O modules to the CPU rack.

8. Right click on the 1769-L18ERM-BB1B controller and select Configure CompactLogix L1x Chassis:

9. In the Configure CompactLogix L1x Chassis dialog, change the number of 1734 Point I/O Modules to 0
by using the down arrow.

Click OK.

Adding the Device Level Ring Ethernet/IP

Next, we need to connect the L18ERM processor to the Ethernet/IP network.
10. Right click on the processor and select Connect to EtherNet/IP Network > Connect Port 1 to a new
Ethernet/IP Network > Standalone Device Level Ring:

IAB displays the New Network dialog. Type in the name CompactLogix DLR as the network name and click
OK.

Select Copper as the default trunk type and click OK:

Enter the IP address: 192.168.1.2, click OK.

IMPORTANT NOTE:
Why chose 192.168.1.xxx?
Because while the first three octets are fixed at 192.168.1 into devices like the 1756-ENxT, 1734-AENT, K6500,
CIP-Encoder and others. Any installer can set the last octet easily and manually via thumbwheel or rotary
switch,. This means commissioning a new machine and/or replacing a faulty device can be done easily, quickly
and without any software tool.
Why did we chose xxx.xxx.xxx.2?
Because according to the IP standard, the first address in a Subnet (in our case 192.168.1.0) is reserved for the
network. On the other hand as a best practice the next available address is used for the gateway that is
192.168.1.1 . This leaves us with 192.168.1.2 as the first available address.
IAB informs you that the processor you just created is being designated as the default processor for
the CompactLogix DLR EtherNet/IP network. Click OK:

11. Click on the Networks tab at the bottom left pane. IAB shows the Infrastructure View of the
CompactLogix DLR EtherNet/IP network with the ring topology the CompactLogix controller is connected
to:

12. Click the Ring001 tab to see the CompactLogix controller:

Adding the Remote I/O Modules

Next, we will add Distributed Point I/O to the CompactLogix DLR EtherNet/IP network.
13. In the EtherNet device list, Expand the Distributed I/O and In-Cabinet Distributed I/O under Point I/O
> Communication Adapter, find the 1734-AENTR module and drag to the right of the CPU (see next
two pictures).

IAB adds POINT I/O chassis to the ring:

Next, we need to configure the Distributed Point I/O and add I/O modules to it.

14. Right click the Point I/O and choose Go to Chassis :

15. The Point I/O appears in the hardware View, click on the Configure chassis button:

16. In the Configure 1734 Chassis dialog, change the number of Modules for Bank #1 to 6. Click OK.

Next, we will add 5 modules to the Point I/O chassis.

17. In the device list find the Point I/O folder. Expand the I/O Module folder, then the Digital folder, and drag
one 1734-IB8 module and one 1734-OB4E module to the chassis:

18. In the device list, find the Point I/O Analog folder and drag a 1734-IE2V and a 1734-OE2V module to the
chassis:

19. In the device list, find the Point I/O folder. Expand the I/O Module folder, then the Specialty Module
folder, and drag one 1734-VHSC24 counter module to the chassis:

Adding the HMI PanelView Plus

You have configured the Distributed Point I/O, now we will add a PanelView Plus 6 600 to the network.

20. Open the Network View (click the Network tab and select Ring001):

21. In the device list find the Computers and Operator Interface folder. Expand the Graphic Terminals
folder, then the 2711P PanelView Plus 6 folder, expand the PanelView Plus 6 600 and drag one
2711P-T6C20A8 to the network:

Notice IAB will add n ETAP automatically in order to allow it to join the DLR network. This will keep the topology
easily displaceable on a long distance line without the hassle of a central switch with a star connectivity. We
reduce cable length and installation time.

Notice IP addresses are automatically created in ascending order, but if you can also enter manually any
Address as needed. Simply right mouse click on a device and choose Channel Properties or Channel Port 1
depending on the type of device.
22. At the bottom left pane, select the Hardware View. Right-click on Device001 in the Workspace, click on
Rename Device and type in the name PVP-HMI. Hit Enter.

23. Open the Network View again (click the Network tab and select Ring001):

Adding the Standard Drive and Motion Drives

Next, we will add a PowerFlex 525 drive to the network.
24. In the device list find the Drives and Motors folder. Expand the AC Low-Voltage folder, then the Compact
Drives folder, Expand PowerFlex525 folder and drag a 25B*** w/ 25-COMM-E2P to the network:

Choosing the PowerFlex525 will launch the RAISE Product Configurator Assistant (just like to ProposalWorks).

25. In the Raise Product Configurator select the following:

26. Make sure the Catalog Number is 25B-A2P5N104 then click Accept when complete.
IAB will add the new PowerFlex 525 to the CompactLogix DLR network.

27. Open the Hardware View. Right-click on Device002 in the Workspace, click on Rename Device and type
in the name PF525-Drive. Hit Enter.

Next, we will add 2 x Kinetix 5500 Servo Drives to the network.

28. Open the Network View and select Ring001 tab:

29. In the device list find the Motion Control folder. Expand the Servo Drives folder, then the Kinetix 5500
folder, Expand Servo Drives folder, find the 2198-H003-ERS servo drive. Hold down the Ctrl key and
drag a 2198-H003-ERS to the network. In the Add Multiple Devices dialog that appears, enter the
number 2 and click OK:

IAB adds two K5500 servo drives to the ring:

You have now built the Midrange architecture in a ring Ethernet network.

Checking the Network Performance

Next we want to run the Ethernet capacity checker in order to see if the CompactLogix5370 L1 controller we have
selected can handle the number of I/O nodes on the Ethernet network.
30. Click on the Capacity button in the toolbar:

31. On the Ethernet Capacity checker, the number of I/O nodes used (4) dont exceed the limit available for
this processor (8):

Click OK, the CompactLogix5370 L18ERM controller we have selected can handle the number of I/O
nodes on the Ethernet network.
Note:
I/O nodes refer to physical devices or adapters controlled remotely, meaning added into the I/O Tree in your
Logix project. If capacity is exceeded and you need actually more standard drives, more motion axis, more
Distributed I/O or other devices you need to physically control then you will have to select a higher processor
type.
The next step in making sure the architecture has no potential bottlenecks is to check the CPU performance in
terms of Network and Controller utilization. This can be easily done via the advanced performance checker
where you can customize what the system has set as the typical configuration.

32. Please click on Edit Advanced Performance . Here is a quick overview of the different sections

33. In this window you can adjust parameters to see what effect the adjustments might have on network
performance. For example, notice that the Average Comm Controller Utilization % is at 0.9% and the Average
Comm Controller Utilization is at 23.1%.
Since we have two motion axis we will check what would happen if changing the parameters related to CIPMotion and Network I/O. Set the parameters as in the picture below:

You will notice the last parameter going to 55.4% and turning yellow. This is a warning to notify that the load on
to the communication side of the controller is over 50%.
What parameter had the most impact?

Before continuing, save your work by clicking the Save button on the IAB tool bar.

Performing a general check

Now we can run a sanity check over all the architecture
34. Click on the Project Completeness Wizard button in the IAB toolbar. IAB displays the General Check
dialog for this project:

The Project Add-ons tab will show what additional tools or components have been configured so far. As you
may notice we have only which means the core automation hardware necessary to run and control the machine.
The other 4 Add-ons refer to:
Software necessary to Design & Configure, add Information & Data, Asset Management, and Visualize
your production.
infrastructure 4 Architecture: here you can add Rockwell default Input Devices, Output Devices, Wiring
Solutions, and Protection Solutions to your project from this dialog. There are also shortcuts to manage
profiles and view the current i4A bill of materials (BOM)
Control Power devices: here you can add all power necessary to the intelligent devices. The wizard it will
check if the power supplies are sufficient.
Field Power: here you can add all the field power necessary to the I/Os and other devices.

35. Click on the Project Checker tab, expand the Standalone Processors, Networks and Other Hardware
folders, and then check Show All Messages.

Make sure that no errors have been detected in your project and click OK.
Now we will add the necessary software to be able to program and configure the system. Obviously the easy way
is to use the wizard and in this case we can simply run again the Project Completeness Wizard.
36. This time we select the Software Wizard

37. The next popup window allows the selection of all and any software. Select the Design &
Configuration tab and click on RSLogix 5000 Select button.

38. Lets add 1 Mini Edition license to the project.

As a PanelView Plus has been included in the project, we will need the development tool. In this case the
best solution to be able to develop any size Operator Panels and any kind of application, would be the
FactoryTalk View Studio Machine Edition:
a. FactoryTalk refers to the technology in common with all our software solutions.
b. View Studio refers to the development version of our visualization package from OP to full
distribute SCADA solutions.
c. Machine Edition refers to the version of tool dedicated to PanelView Plus products.
39. Move to the Visualization Tab and select the 9701-VWSTMENE and add one licence

What about the runtime license?

Note: it is always important to check if the end user needs any additional tool to optimize the capabilities
of the machine/line/plant in order to maximize the ROI

Adding Infrastructure 4 Architecture using the Wizard.

Now that we have the automation architecture and the software necessary to configure, program and run the
application we would need to add all necessary components attached to the machine.
40. Please open again the Project Completeness Wizard and select the I4A Wizard option

Click the I4A button in the IAB toolbar. IAB opens the I4A wizard to the Overview tab.

The icons on the left of the window show the categories of devices that the wizard can add
to the IAB BOM. These icons serve as buttons to open the different pages of the wizard for
further refinement of the devices that will get added to the BOM.

The list of checkboxed items let you select the categories you want to include in the IAB
BOM. If a box is checked, the items for that category will be added to the BOM. If the box is
not checked, nothing will be added to the BOM for that category.

The Manage Profile button lets you select from among profiles that specify how the devices
in the categories are chosen by the wizard. The wizard comes equipped with 4 default
profiles (1 for each major region) that will default the products chosen to standard industry
default products. The profile section also has the ability for you to create and manage your
own custom profiles for applications you typically encounter.

The View I4A Bill of Material button lets you preview the I4A wizard selections.

IMPORTANT NOTE: THIS SECTION IS A COPY OF THE STANDARD LAB FOUND IN THE IAB HELP. FOR THIS
REASON YOU WILL HAVE DIFFERENT VALUES ON YOUR SCREENS THEN THE PICTURES IN THE MANUAL.
Anyway, what is important is to practice on adding what we call the attachments because only by doing this
we can really offer a turnkey solution. By leveraging IAB simply adding Software, Sensors, Power Supplies,
we can create a professional offer to present to our custoemrs.

41.

Click the Manage Profiles button.

The wizard displays the Manage Profiles dialog.

The checkbox next to

the profile indicates
that it is the default
profile that will be
used each time the
i4A wizard is run for
st
the 1 time on a
given project.

Four profiles are listed:

RADefaultAsia Pacific: default profile for use in Asia Pacific

RADefault-EMEA: default profile for use in EMEA

RADefaultNorth America: default profile for use in North America

RADefaultSouth America: default profile for use in South America

42. In this lab, we will use the RADefault - EMEA profile. Highlight the RADefault-EMEA profile and click
Apply Profile.

Click OK to close the profile manager.

43.

Check all the check boxes for I4A categories and click the View I4A Bill of Materials button.

The I4A BOM is generated and displayed. This may take a minute.

The catalog numbers and quantities in this BOM are based on the default settings built into the
profile you selected and the quantities of I/O from the IAB configuration. The devices have been
grouped in the BOM so that you can easily see the input, output, wiring, and protection devices that
have been added to the project BOM.

The design of i4A is such that this is the minimum amount of work you need to do to get a
representative sample i4A BOM into your IAB project. In many cases, these steps are enough for a
budgetary analysis of a complete system. If your system requires more advanced selection, follow on
to the next steps of the lab where we will demonstrate how to use the detailed selection criteria to
generate a more accurate budgetary analysis including i4A components.

It is important to note that all of the i4A devices incorporated in this wizard are intended to be
representative catalog numbers added to the BOM for the products in your project. There are
instances where the voltages or application of devices may not represent what the final
project actually requires. It is your responsibility to review the devices added to the BOM
before ordering.

Click Close on the Quick Bill of Materials dialog.

44.

Now uncheck the Input Devices check box and click the View I4A Bill of Materials button.

The I4A BOM is generated and displayed without any input devices. This may take a minute.

Click Close on the Quick Bill of Materials dialog.

45.

On the Overview page, click on the Input Devices image on the left side of the UI.

46. . In the UI you will see 3 main sections.

a.

At the top left there is a summary of Input Points from the project. This is based upon any
Input modules you currently have included in your IAB project. In addition, there is a Total
points selected summary that is the total of all the points currently accounted for as part
of the i4A input devices.

b. On the top right you can change the percentage breakdown of Input Devices, manually
change the quantities, or go into Detailed Configuration for a more granular breakdown of
devices.
c.

Along the bottom of the UI is the grid of items that will be included in the BOM as part of
the selected input devices above.

When you look at the UI, you will notice that all of the quantities are zero. This is because we
previously (section 3 step 1 above) unselected the Input Devices which effectively clears out all of
the default selections from the Input Devices page.

Go back to the Overview page by clicking on the Overview image on the left side of the UI.

Recheck the Input Devices checkbox. Now navigate back to the Input Devices page (click on the
Input Devices image on the left side of the UI.)

You will now see quantities based upon the default profile you have selected.

47. Now lets see how changing the % of certain device types impacts the BOM. Make the following
changes in red:

You will see that the Quantities for the devices in green also get updated. Furthermore, if you
were to manually change the quantities in either the Qty based upon % field or in the grid at the
bottom, you will see the other values, including % of Inputs change. Make the changes below in
red:

The important thing to remember is that changes to the % of Inputs, Qty based upon Inputs,
and quantities in the grid will automatically recalculate the other items to keep the relationships of
data in sync.

48. You may have noticed the Detailed Configuration button to the right of each category of
devices. Click on the Detailed Configuration button to the right of the Push Button row.

49.

In the Advanced Configuration UI you will see items that you can modify to further refine the type
of devices you are including in your BOM. Make the following changes and click OK.

Notice in the BOM grid how the type of Push button changed from 800F to 800T as well as the
quantities.

50.

Similar Detailed Configuration options exist for the other types of standard devices as well. Take
a moment to look through those dialogs.

51. In some cases, the standard commonly used devices may not be enough to represent the i4A
products you wish to add to the BOM. For these cases, click on the Custom Device Detailed
Configuration button. This will launch a limited subset of the Rockwell Automation Product
Library. From here you can navigate to a particular group of products and configure the exact
catalog number you wish to include. As an example, browse to the 42EF RightSight 18mm
Right Angle sensor.

52.

Click OK to launch the configurator and make the following selections then press Accept.

You will see the custom device is added to the BOM. Adjust the quantity in either location to 10
devices.

53. Output Devices follow very similar concepts to Input Devices. In this section we will walk through
some minor differences, but skip over much of the functionality. On the right side of the UI click on
the Output Devices button.

54. In the output devices page you will be able to add Tower Lights, Beacons, Horns, Counters,
Relays, Pilot Lights, and Custom Output Devices. Please take a moment to look through the
Detail Configuration items to get a feel for the types of customization that can be achieved.

55.

The main difference between input and output devices is that we have distinguished between the
AC and DC outputs as part of your project. For the purposes of this wizard we have made the
assumption that all AC Outputs are considered 120V AC and all DC outputs are 24V DC.
Through the course of your project you might find it helpful to differentiate the type of output
device based upon whether it is AC or DC. In some cases the output devices themselves are
AC/DC so it really doesnt effect the outcome of the BOM, but in other cases it may change the
catalog number selected.

56. Take a moment to explore with the different functionality here.

57. Wiring Solutions follows a new selection concept in the wizard that allows for selection of
Terminal Blocks or Wiring Systems. On the left side of the UI click on the Wiring Solutions
button.

The wiring solutions UI is designed to allow for customization of your wiring based upon the I/O
modules currently in your project. Make the changes below to see how the grid updates.

Quantity and Catalog

number of I/O Modules in
your Project.

Terminal Block
selection for the I/O
module

Quantity of Terminal
Blocks required for
standard wiring of
module

Quantity of End Anchors, End Barriers, and

Grounding Blocks based upon the
parameters at the top of the UI.

Changes to the above grid are directly reflected in the BOM that is generated. This UI acts as the
customization mechanism and the BOM display mechanism.
58. . Now select Wiring Systems at the top of the UI and make the following changes to the UI:

Quantity and Catalog

number of I/O Modules in
your Project.

Much like the Terminal Block selection, this UI is also I/O module driven. The BOM output of this
UI will contain Wiring System Interface Modules and the required pre-wired cables to connect the
wiring system module to the I/O module.
In the above example, we used the Terminals filter to limit the choices of W iring System to only
those that had removable terminals. You can also use Style and Features as other potential filters
to help you select the appropriate wising system for your application.
It is important to note that any I/O modules that already contain an On-Machine Solution
will be duplicated in this UI. It is recommended that you use one method or the other when
configuring your project.

59.

Once you have had a chance to review the W iring Solutions page, click on the Circuit Protection
button on the right side of the UI.

60.

The Circuit Protection page analyzes your IAB project for devices that can commonly benefit from
the use of Circuit Protection devices. These include I/O Modules, multiple types of power
supplies, HMIs, and Transformers. Based upon the quantities of devices in your project, the
wizard calculates approximate quantities of circuit protection devices that your project may
require.
Number of circuit protection
devices per module in your project.

Quantity of items in
your project

Type of circuit
protection device to
use

Calculated quantity
of circuit protection
devices

Resulting BOM from

selections above.

In the above example you can customize the type of circuit protection device you would like to use
for each line item in your project. To customize the quantities, you can either adjust the 1 CP per x
Modules or adjust the quantities directly in the Qty field on the right side of the UI or in the BOM
grid.
61.

Click on the Power Solutions button on the right side of the UI.

62. The Power Solutions page provides assistance in selecting UPSs and Transformers for any AC
power supplies present in your project. It also provides a launch point for a new Control Power
and Field Power selection wizard. These wizards will be discussed in the Control and Field Power
lab.
To configure devices necessary to support any AC power supplies in your system click on the
Add UPS button and select 1609-P Commercial Series Uninterruptible Power Supplies and
click OK.

Make the following UI selections and press Accept.

Now click on the Add Transformer button and select 1497 Control Circuit Transformer and
click OK.

Make the following UI selections and press Accept.

Now change the quantities in the BOM section for the configured UPS and Transformer.

63.

Go back to the Overview page and click on the View i4A Bill of Material button to review the
changes you have made.

64. From the Overview page, click on the Manage Profiles button.

65.

Throughout this lab we have been making changes to various items on the Input Devices, Output
Devices, W iring Solutions, and Circuit Protection pages. Many of these items can be saved in a
profile for use later. The profile mechanism is designed to allow you to customize settings on the
various pages so that you can apply them to different IAB projects at a later date without having to
re-enter all of the customization. To create a profile, review the UI and make sure you have all the
appropriate items selected and then click the Save Profile button. Name the profile Lab Profile.

This profile will be saved in a list of user profiles for you to access later. Since this is a lab profile,
we will highlight it an click Delete Profile.

66.

Using custom profiles is a powerful mechanism designed to allow you to create commonly used
i4A settings for multiple customers. The profile has the ability to store the following settings for
future use:
a. Input Devices page:
i. % of Inputs

ii. Detailed Configuration settings (from all dialogs)

b. Output Devices page:

i. %AC / %DC

ii. Detailed Configuration settings (from all dialogs)

c.

Wiring Solutions page:

i. UI Selections

d. Circuit Protection page:

i. UI Selections:

e. Power Solutions page:

i. No parameters saved in profile.
This concludes the i4A W izard lab. You have learned how customize your i4A products and manage
profiles. For information on the Control Power wizard and Field Power wizards, run the Control & Field
Power lab.

76

View the Bill of Material

In IAB, there are two kinds of BOM:
Quick BOM - Shows the BOM for only the active window.
Project BOM - Shows the BOM for the entire workspace.
We will show the BOM for the entire project.
67. On the toolbar click the Project BOM button:

Click yes to save changes to the project.

68. The full Project BOM for the project appears. All parts in the project are listed, along with pricing
information.

There are three different options you can use to view the Project BOM: Organized BOM,
Consolidated BOM, and Positional BOM.
69. Notice there are buttons at the bottom of the BOM window which also enable you to print the BOM
or export it in Excel or XML format:

77

Close the BOM window and save your work by clicking the Save button on the IAB tool bar.

Sharing the BOM with ProposalWorks (ONLY READ THROUGH)

In the latest versions of IAB and ProposalWorks we have added new options to enhance the interaction
between the two tools and make sure any solution would result in a complete list of hardware and software
in the Bill of Material.
There are actually three options:
A. create an IAB project, export it to PW and keep IAB as the editor for the architecture material
B. create an IAB project and simply export the BOM to PW
C. create a ProposalWorks project and open IAB from inside PW
Lets review more in details what is possible:
a. with option A you will use both tools.
i.
open IAB and open or create a project
ii.
export the project to ProposalWorks from the Menu File
iii.
click Yes to the question proposed

iv.

the complete BOM is now inside PW and there you can add push buttons, photo eyes, lights
and so on. As soon as you need to edit, add or modify any part of the automation
architecture you simply need double click on Integrated Architecture Builder

v.

IAB opens and any saved modification will reflect in the PW project

78

b. with option B once the project is exported from IAB to PW, there is no longer any need for IAB
i.
open IAB and open or create a project
ii.
export the project to ProposalWorks from the Menu File
iii.
click No to the question proposed

iv.
c.

the complete BOM is now inside PW and there you can manage any device.

with option C you start a project with PW and as soon as you need to add automation devices and
design an architecture you can launch IAB from within PW.
i.
to launch IAB, simply select the Tools icon on the top bar and click on the Integrated
Architecture link

ii.

notice in this case there is NO IAB project.

79

IMPORTANT
As far as options A and B are concerned you can achieve the same result by creating a ProposalWorks
project and then importing an IAB project from PW and selecting Yes or No to the similar question as
proposed by IAB

This completes the IAB Midrange lab exercise.

80

___________________________________________________________________________________

Comparison between Midrange and Connected Components solutions

In this chapter we will give some simple guidelines to help you compare the two architectures considered in
this Lab. In order to make it more effective we have split the chapter into the major technologies involved. In
each section of this chapter we will show a table to summarize the most important specifications and then
the benefits they bring to the solution.
But before we start the comparison, we will use once again IAB to help us. The best way to help in this case
is to have a clear view of both solutions and this can be achieved generating a Report.
Thanks to IAB the reports can be customized to be more or less detailed, this allows the architect to:
have a global view
check for any missing product/component/solution
print and leave a copy to a customer
use it as a proposal
review the specifications.
or, it can be used to easily compare different solutions.

81

Lets create two reports, one per project.

1. Open both IAB projects. Select Option > Report Options

The Report Options window allows the selection of

a. different languages,
b. a list of items to include in the report
c. the Author details.
2. For the purpose of this Lab we will select the options as shown below. Feel free to enter
Author, Company and the other fields as you like

Apply the same settings on both projects then click OK and save.

82

3. Please be sure to replicate the same settings in both projects then select the MSWord icon
on the top right menu bar to create the project report and create both reports

Simply follow the instruction in the next few popup windows by always selecting Yes. At
the end of the process the report will open in MSWord.
TIP: MSWord allows setting up a side by side view with synchronous scrolling. This can be
very useful when comparing two documents

If you now scroll through the two reports you can compare the options and have a deeper view
into what each of the two architectures will bring.
As an example you can see in the Network Details section the difference between the CC and
the IA solution. The first will not give any detail because communication relies on messaging.
This means it depends on the code and the network load.
The IA solution instead, will show all the communication details because the platform is
developed to manage the integration of all controller tasks including the communication. This
means I dont have to guess what the CPU can or cannot communicate.

83

Now that you have the reports on one hand and the specs in the following pages, you can start
comparing features and options to try and match the customer needs.
As a good example we have used is the Vertical Form Fill Seal in the appendixes. Such an
application can span from very simple stand alone to very complex and fully integrated into a
production line.

84

Controllers Comparison
CompactLogix
1769-L18ERM-BB1B

User memory

512 KB (1)

MicroLogix
Micro850
2080-LC50-48QBB
140 KB (2)
Estimated including
program and data

Secure Digital
1784-SD1 (1 GB), shipped with controller
1784-SD2 (2 GB)

2080-MEMBAK-RTC for830
and 850 only

Built-in ports

2 EtherNet/IP
1 USB

- USB 2.0 (non-isolated)

- RS232/RS485 nonisolated combo serial
- 10/100 Base T Ethernet
port (RJ-45)

Communication options

Dual-port EtherNet/IP (DLR support)

1 Ethernet port

Controller application

Midrange applications
Embedded 1734 I/O modules

Small applications
Low cost applications

Controller Programs/tasks

32 tasks
100 programs/task

Embedded I/O modules

16 DC digital inputs
16 DC digital outputs

Module expansion capacity

8 POINT I/O modules (3)

Motion Axes Type

Supports up to 2 CIP axes

Memory card

Up to 256 programs may

be included in a project,
depending on available
controller memory
28 DC digital inputs
20 DC digital outputs
- 5 Plug-In Ports
4 Expansion Modules
Up to 3 axis of PTO motion
for basic positioning

(1) The memory in a CompactLogix controller is split in I/O memory and user memory.
I/O memory depends on the number of: Controller tasks, I/O points, DeviceNet modules, Other
communication modules, Motion axes, and any device in the I/O tree. Anyway the IAB provides a precise
estimate of the I/O Memory.
user memory depends on the code and the variables added to the project. Note its a best practice to
reserve 20 to 30% of controller memory for future expansion.
(2) CCW will display only memory used and memory left for Programs and Data.
(3 ) 1734 POINT I/O modules can be used as an expansion to the controller rack.

85

Integrated Solution Benefits

Controllers Integration
Development Scalability

CPU interlocking (peer to peer I/O communication)

Code reuse from L1y to L7x

Knowledge Integration
Knowledge Integration

Extended troubleshooting
Automatic Device profiles creation (AOP)

System Capability

Priority based multitasking

Development tool

Studio5000 Logix Designer high level hardware and software

integration. No need for any other tool, no data duplication, concurrent
programming.

Connected Component Solution Benefits

Controller
Communication
Servo Drive Support
Development Tool

CPU Messaging
Low Power Range (0.05-3KW)
Connected Component Workbench.
A free tool Single application for component class products
Reduces acquisition, training and support costs

2080-IQ4
2080-OB4
2080-OV4
2080-OW4I
2080-IQ4OB4
2080-IQ4OV4
Plug-ins expandability

2080-IF4
2080-IF2
2080-OF2
2080-RTD2
2080-TC2
2080-TRIMPOT6
2080-MOT-HSC
2080-SERIALISOL
2080-DNET20
2080-MEMBAK-RTC

4-pt Digital Input, 12/24VDC, Sink/Source, Type3

4-pt Digital Output, 12/24VDC, Source
4-pt Digital Output, 12/24VDC, Sink
4-pt Relay Output, Individually Isolated, 2A
8-pt Combo: 4-pt Digital Input, 12/24VDC, Sink/Source,
Type3, and 4-pt Digital Output, 12/24VDC, Source
8-pt Combo: 4-pt Digital Input, 12/24VDC, Sink/Source,
Type3, and 4-pt Digital Output, 12/24VDC, Sink
4-ch Analog Input, 0-20mA, 0-10V, non-isolated 12-bit
2-ch Analog Input, 0-20mA, 0-10V, non-isolated 12-bit
2-ch Analog Output 0-20mA, 0-10V, non-isolated 12-bit
2-ch RTD, non-isolated, 1.0 C
2-ch TC, non-isolated, 1.0 C
6-ch Trimpot Analog Input
High Speed Counter, 250kHz, Differential Line Receiver,
1 Digital Output
RS232/485 isolated serial port
DeviceNet Scanner, 20 Nodes
Memory Backup and High Accuracy RTC

86

Human Machine Interface (HMI) or Operator Panels Comparison

PanelView Plus 6 600

2711P-T6C20A8
Communication protocols
supported

PanelView Component C600

2711C-T6T

Serial RS-232
(DF1 or
DH-485)
Ethernet
1 USB host and 1 USB device
Mid-size application requiring
fewer displays and alarms

Serial RS232
Serial RS422/RS485
1 USB host and 1 USB device
EtherNet
Small application with a reduced cost

Display

5.7 in.
Color TFT

5.7 in.
Color TFT

RAM

256 MB

64 MB

Internal Storage
External storage
Operator input
Programming Software

512 MB
Secure Digital (SD) card
Touch screen
FactoryTalk View Machine
Edition software

64 MB
Secure Digital (SD) card
Touch screen
Web-enabled software resident in
terminal or PC-based software,
DesignStation 2.0 or later

Preferred controller
Capabilities

Logix controllers.
Multi-network/multivendor
connectivity
Multi-control connectivity
Recipes
Trending
Data logging

MicroLogix, SLC, Micro800 controllers.

Single device
<20 displays
<100 alarm messages
Recipe upload/download
Trending
Data logging

Application

87

Integrated Solution Benefits

Controller Integration

Direct referencing of Logix tags, zero development time

Run time license

Free FactoryTalk View Client comes installed and activated

Graphic tools

Free downloadable Pre-engineered faceplates for motion,

process, drives and any Rockwell device

Connectivity Features
Additional Features

Supports remote connectivity (VNC and FTP)

Provides remote recipe and data management through
.CSV files
Includes built-in PDF viewer for context-sensitive operator
support
Supports DataStore Plus logging and trending, which
eliminates the 300,000 data point limit

Connected Component Solution Benefits

Controller Integration

CPU Messaging

Cost effective solution

Fully featured Component-level device for small applications

Development Tools

- Connected Component Workbench (CCW) a simplified and

easy to use development environment, or
- Web Browser

88

Motion Servo Drives Comparison

Kinetix 5500
2198-H003-ERS
Number of axes

Kinetix 300
2097-V32PR0

2 CIP axes with L18ERM

controller

3 PTO axis with Micro 850 controller

Yes

No

Logix5000 (c.ca 43 advanced

motion instructions)

PLCOpen (positioning, IEC 61131-3

standard motion instructions)

ControlLogix, CompactLogix
(with Built-in Motion Support),

ControlLogix, CompactLogix (with Builtin Motion Support), MicroLogix,

Micro850

Yes

Yes

CIP Motion
Motion Instructions

Controller compatibility

EtherNet/IP Networking
Safe torque-off

Safe torque-off

Safety features
1-Phase, 240V, 1.4A

1-Phase, 240V, 2A

Communication options

Dual-port EtherNet/IP

1 Ethernet port

Rotary motors compatibility

VPL servo motor and induction

motors

MP-Series
TL-Series

Linear motors compatibility

N/A

LDC-Series Iron Core

LDL-Series Ironless
Single-axis

Electrical input specs

Drive configuration
Refers to hardware
installation

Single-axis operation or
Multi-axis bus-sharing
configurations

89

Integrated Solution Benefits

Servo Drive Scalability

Wide Power Range (0.4-22KW)

System capability
Application Support

Multiaxis synchronization (Camming)

Coordinated Motion (Robotic support)

Knowledge Integration

Hardware Integration

Configuration and Control strategy all included in the CPU

K5500 Benefits
Single motor cable that includes power, feedback,
and brake conductors with SpeedTec connector

Motion Control

High performance in a smaller footprint and optimized power

density

System Integration

Digital feedback device provides real-time motor

performance information to the control circuitry

Connected Component Solution Benefits

Servo Drive Support
Application Support

Small Motors Support (0.05-3KW)

Single-axis solution for low-complexity motion applications
Flexible control architecture for simple analog, PTO, or
EtherNet/IP Indexing control
Low-cost EtherNet/IP network solution

90

Networks topologies and protocols Comparison

CompactLogix L18

Micro850

Ethernet Topology
Ring
Star
DLR

Yes
Yes
Yes

Ethernet/IP
Modbus
DeviceNet

Yes
No
No

No
Yes
No
Protocols

Network connections
EtherNet/IP nodes in a
single Logix Designer
application, max

Yes
Yes (embedded port + plugin)
Yes (new plug-in)

256 CIP Connections;

120 TCP(Physical Devices)
8 (1)

Ethernet only messaging

supported
I/O Connections via DeviceNet
N/A

(1)

The number of nodes listed for CompactLogix 5370 controllers represents the maximum number of
EtherNet/IP nodes you can include in a Logix Designer application project. For example, in a Logix Designer
application project that uses a 1769-L18ERM-BB1B controller, you can only add as many as 8 EtherNet/IP
nodes to the project (ex. 8 x 1734-AENT)

Integrated Solution Benefits

Clock Synchronization

CIP-Synch automatic clock synchronization for motion,

alarming, events and fault finding with precise time stamping

Integration

Seamless integration with any IA solution (ex. can control a

ControlLogix rack via 1756-EN3TR)
CIP-Synch, CIP-Safety, CIP-Motion, CIP-Energy,

Resiliency

One single point of failure proof

Scalability

Connected Component Solution Benefits

Serial Port Protocols (830/850)

Modbus RTU Master and Slave

CIP Serial Client/Server (RS-232 only)
ASCII

Ethernet Port Protocols (850)

EtherNet/IP Client/Server
Modbus/TCP Client/Server
DHCP Client

Plug-ins

DeviceNet (2080-DNET20)
Serial (2080-SERIALSOL)
SMS (Prosoft)

The traditional EtherNet/IP network topology has been a star, where end devices are connected and
communicate with each other via a switch. The EtherNet/IP embedded switch technology, or DLR, offers
alternative network topologies for interconnecting EtherNet/IP devices by embedding switches into the end
devices.

91

Standard Drives Comparison

Standard drives is a very important part of any automation solution. Almost any machine and any application
will need some mechanical part to move and this is why we have the greatest portfolio of products in our
offering. Furthermore, we have made it possible for any of our Micro and Logix Controllers to connect and
control such devices. The on key differentiator between the two solutions will be the level of integration. This
means, while with a Logix controller it is possible to import automatically the full list of parameters, on the
Micro this step has to be done either manually or by preparing and prebuild function block.
Notice we use to have two classes of drives: PF4 and PF7, where now with the latest development we are
launching a new family called PowerFlex5.
Since the list of options and features to compare would be rather too long we show here only a list of
communication options. In case you need more detailed specifications please find the links to the technical
data at the end of this section

Communication
Options

Default

Optional

DSI (serial RS485)

External Gateway:
BACnet
ControlNet
DeviceNet
EtherNet/IP
LonWorks
PROFIBUS DP

DSI (Serial RS485)

Can be master for up to 5 drives

Internal Communication Card:

BACnet
ControlNet
DeviceNet
EtherNet/IP
LonWorks
PROFIBUS DP

PowerFlex 523

DSI (Serial RS485)

Can be master for up to 5 drives

PowerFlex 525

Embedded Ethernet/IP
DSI (Serial RS485)
Can be master for up to 5 drives

Dual-Port EtherNet/IP
Adapter

Catalog Num. 20-COMM-ER

Internal Communication Card:

Dual Port EtherNet/IP
BACnet
ControlNet
DeviceNet
LonWorks
PROFIBUS DP
Internal Communication Card:
Dual Port EtherNet/IP
BACnet
ControlNet
DeviceNet
LonWorks
PROFIBUS DP
Compatibility products:
- PowerFlex 70, 700, 700H,
- 700S and 7000 AC drives
- PowerFlex DC drives
- SMC Flex and SMC-50
- Other DPI-based host devices

PowerFlex 4 / 4M

PowerFlex 40 / 40P / 400

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Communication Options
PowerFlex 7Family

BACnet/IP Option Module 20-750-BNETIP

Coaxial ControlNet Option Module 20-750-CNETC
ControlNet Communication Adapter (Coax) 20-COMM-C
ControlNet Communication Adapter (Coax) Conformal Coat 20-COMM-C-MX3
DeviceNet Option Module 20-750-DNET
DeviceNet Communication Adapter 20-COMM-D DeviceNet Communication
Adapter Conformal Coat 20-COMM-D-MX3
Dual-port EtherNet/IP Option Module 20-750-ENETR
EtherNet/IP Communication Adapter 20-COMM-E
EtherNet/IP Communication Adapter Conformal Coat 20-COMM-E-MX3
HVAC Communication Adapter (Only Modbus RTU can be used) 20-COMM-H
CANopen Communication Adapter 20-COMM-K
LonWorks Communication Adapter 20-COMM-L
Modbus/TCP Communication Adapter 20-COMM-M
Profibus DPV1 Option Module 20-750-PBUS
Single-port Profinet I/O Option Module 20-750-PNET
Dual-port Profinet I/O Option Module 20-750-PNET2P
PROFIBUS DP Communication Adapter 20-COMM-P
ControlNet Communication Adapter (Fiber) 20-COMM-Q
Remote I/O Communication Adapter 20-COMM-R
Remote I/O Communication Adapter Conformal Coat 20-COMM-R-MX3
RS485 DF1 Communication Adapter 20-COMM-S
RS485 DF1 Communication Adapter Conformal Coat 20-COMM-S-MX3

Technical Data
Documents

PowerFlex4M
PowerFlex4/40
PowerFlex 520
PowerFlex70
PowerFlex700
PoweFlex750
PowerFlex7000

Safety Solutions
Active Front End

Link to ab.com
Product Profile in English
Multi Language Literature

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Appendix A: Quick Selection Reference

Select a CompactLogix System: CompactLogix System Selection Guide Manual 1769-sg001_-en-p.

94

Select a Micro800 Controller: Micro800 Selection Guide Manual 2080-sg001_-en-p.

Select a Servo Drive System: Kinetix Motion Control Selection Guide Manual gmc-sg001_-en-p.

95

96

97

98

Select an HMI: Visualization Solutions Selection Guide Manual view-sg001_-en-p.

99

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___________________________________________________________________________________

Appendix B: CIP Connections Quick Reference

RPI: The requested packet interval (RPI) defines the frequency at which the controller sends data to and
receives data from I/O modules. In the programming software, you set an RPI rate for each I/O module in
your system, including embedded I/O modules, local expansion modules, or distributed I/O modules over an
EtherNet/IP network. You set an RPI rate for each I/O module in your system.

Scan time:

CompactLogix 5370 L1 controllers always attempt to scan an I/O module at the configured RPI rate. For
individual I/O modules, a Module RPI Overlap minor fault occurs if there are enough I/O modules with RPI
rates set too fast that they cannot all be serviced in the allotted interval.
The specific configuration parameters for a system determine the impact on actual RPI rates. These
configuration factors can impact the effective scan frequency for any individual module:
Rates at which other 1734 POINT I/O modules RPI rates are set
Number of other 1734 POINT I/O modules in the system
Types of other 1734 POINT I/O modules in the system
Application user task priorities
In general, follow these guidelines when setting the RPI rates in a CompactLogix 5370 L1 control system:
For digital modules:
12 modules can be scanned in 2 ms.
34 modules can be scanned in 4 ms.
58 modules can be scanned in 8 ms.
IMPORTANT When considering digital I/O modules, remember that they can be the embedded I/O module
on the controller or
1734 POINT I/O modules used as local expansion modules. Therefore, the consideration for using two
modules can be the
embedded I/O module and a 1734 POINT I/O module or two 1734 POINT I/O modules.
For specialty and analog modules (except 1734-485ASC modules):
1 module can be scanned at 20 ms.
For each additional module add 20 ms.
For example, if a CompactLogix 5370 L1 control system uses two analog modules, the module can be
scanned in 40 ms.
For 1734-485ASC modules, the sum total data size for all ASC modules determines the RPI rates:
For total data size less than 20 bytes, each module can be scanned in 20 ms.
For data size greater than 20 bytes, use the size value as the RPI.
For example, if the total data size is 40 bytes, each ASC module can be scanned in 40 ms.
You are not required to set individual 1734 POINT I/O modules RPI values to the values listed above. For
example, ifyour application scans one or two modules, you do not have to use RPI rates of 2 ms.
Remember, though, that higher RPI rates result in scanning the data less frequently.
The RPI shows how quickly modules can be scanned, not how quickly an application can use the data. The
RPI is asynchronous to the program scan. Other factors, such as program execution duration, affect I/O
throughput.

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Controller Connections
A CompactLogix system uses the connection types to establish communication links between devices:
Controller-to-local I/O modules or local communication modules
Controller-to-remote I/O or remote communication modules
Controller-to-remote I/O (rack-optimized) modules
Produced and consumed tags
Messages
Controller access by the programming software
Controller access by RSLinx Classic software for HMI or other applications
You indirectly determine the number of connections the controller uses by configuring the controller to
communicate with other devices in the system. The limit of connections may ultimately reside in the
communication module you use for the connection. If a message path routes through a communication
module, the connection related to the message also counts
toward the connection limit of that communication module.
CompactLogix 5370 Controller Ethernet Node Limits and Connections
When designing a CompactLogix 5370 control system, you must consider the following:
Maximum number of Ethernet nodes available for your controllers project
Connections
The controller you select determines the number of Ethernet nodes available.
Determine Total Connection Use
The total connection requirements for a CompactLogix system include both local and remote (distributed)
connections.
The controllers support these numbers of connections:
1769-L23x and 1769-L3x controllers support 100 connections.
1768-L4x controllers support 250 connections.
CompactLogix 5370 controllers support 256 connections.
The available remote connections depends on the network interface.

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Scan time:

How the PLC operates

The PLC is a purpose-built machine control computer designed to read digital and analog inputs from
various sensors, execute a user defined logic program, and write the resulting digital and analog output
values to various output elements like hydraulic and pneumatic actuators, indication lamps, solenoid coils,
etc.
Scan cycle
Exact details vary between manufacturers, but most PLCs follow a 'scan-cycle'format.
Overhead
Overhead includes testing I/O module integrity, verifying the user program logic hasn't changed, that
the computer itself hasn't locked up (via a watchdog timer), and any necessary communications.
Communications may include traffic over the PLC programmer port, remote I/O racks, and other
external devices such as HMIs (Human Machine Interfaces).
Input scan
A 'snapshot' of the digital and analog values present at the input cards is saved to an input memory
table.
Logic execution
The user program is scanned element by element, then rung by rung until the end of the program,
and resulting values written to an output memory table.
Output scan
Values from the resulting output memory table are written to the output modules.
Once the output scan is complete the process repeats itself until the PLC is powered down.
The time it takes to complete a scan cycle is, appropriately enough, the "scan cycle time", and ranges from
hundreds of milliseconds (on older PLCs, and/or PLCs with very complex programs) to only a few
milliseconds on newer PLCs, and/or PLCs executing short, simple code.

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Connections- A connection is a communication path. Effectively, data passes through

a connection. I/O, messaging, Produced/Consumed tags, RSLinx Connections to PCs
or HMIs all use connections. The number of connections used in a Logix product must
be considered since they take up buffers, resources and memory in both processors
and network cards.

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___________________________________________________________________________________

Appendix C: Device Level Ring Quick Reference

Embedded switch technology is designed to enable end devices to form linear and ring network topologies.

Products with EtherNet/IP embedded switch technology have two ports to connect to a
linear or DLR network in a single subnet.
You cannot use these ports as two Network Interface Cards (NICs) connected to two
different subnets.

A DLR network is a single-fault tolerant ring network intended for the interconnection of automation devices.
This topology is also implemented at the device level. No additional switches are required.
The devices are connected in a closed-loop configuration.

The following are advantages of the DLR network:

Simple installation
Resilience to a single point of failure on the network
Fast recovery time when a single fault occurs on the network

The primary disadvantage of the DLR topology is the additional effort required to set up and use the network
as compared to a linear or star network.

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When to use Device Level Ring (DLR)

Provides resiliency at the device level through dual port devices.

Ideal applications include:

Where there are Low cost and ease of use resiliency requirements

Migration from field bus networks

CIP Motion and CIP Sync applications

Where users do not want to use central switches

Can recover in as fast as 3 ms for a 50 node ring worst case

Lower cost to implement than other resilient network types

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APPENDIX D: IA-VERTICAL FORM, FILL AND SEAL (VFFS) MACHINES

107

APPENDIX E: CC-VERTICAL FORM, FILL AND SEAL (VFFS) MACHINES

108

APPENDIX F: PLCOPEN MOTION CONTROL EXAMPLE

109

APPENDIX G: PTO MOTION CONTROL EXPLAINED

110

Open Loop Stepper Motor System

In the open loop system, a clockwise signal or counter-clockwise signal (determined by the
PLC program) is sent from the interface module to the stepper motor drive amplifier.
This amplifier translates the single pulse train signal sent from the interface module to the
required number of signals for the stator windings of the motor. When applied to the stator
windings, the pulses from the drive amplifier are converted into discrete rotor movements,
or steps.

Rotary stepper motors are typically designed for 0.9, 1.8, 7.5, 15, 45 and 90 degrees of revolution per
pulse. The resolution of the stepper motor (steps per revolution) can be determined by dividing the
stepper angle into 360 degrees. For example, the
0.9degree motor will provide 400 steps per revolution, and the 15degree motor is
will provide 24 steps per revolution. The larger the number of steps the motor provides per
revolution, the better the resolution it will provide. Also note that the higher the resolution, the
slower the speed of the shaft.
Since the rotation of the stepper motors shaft is predictable for a given number of pulses, open
loop systems are quite reliable. A typical system will use a home position which can be
determined with a limit switch to orient the load to a start position. After the home position is
determined, the controller can send the motor a specific number of pulses to cause it to move to a
predetermined location.
The open loop system assumes that if a pulse is received, the motor will increment a step, which will
move the load the designated distance. Inaccuracy of this system may occur if the stepper motor
develops a fault or if the load is obstructed in any way. If your application is prone to such
occurrences, the closed loop system with a shaft encoder providing feedback data of the actual
position of the load may be the best choice. However, even with open loop systems, the normal
safety features built into the drive amplifier system often afford a way to cope with unexpected
faults or obstructions. Most stepper motor drive systems provide circuitry that will detect when the
shaft is stopped for no apparent reason and is not allowed to step the correct number of times. In
such systems, the PLC can be programmed to sense the condition through the system interface,
trigger an alarm, and shut down the system.

111