Allen-Bradley ControlLogix 5570 Series offer memory and speed

Rockwell Automation (www.rockwellautomation.com) has proudly released a range of programmable automation controllers (PACs) that offer manufacturers higher processing speed as it supports over 100 axes of motion. Seamlessly integrating through SERCOS and EtherNet/IP network interfaces, the Allen-Bradley Controllogix 5570 Series features optimized process, safety, motion and information capabilities.

The new series does not only increase the amount of information exchanged between the supervisory layers and the control, but it also boost system performance and improve productivity by enhancing access to real-time information.

Ideally suited for synchronizing complex motion applications, the ControlLogix 5570 Series offers high-speed axis and trajectory planning. With two to three times quicker scan times, the new controllers feature memory options ranging from 2 MB to 32 MB.

The new series includes the ControlLogix 5571, 5572S, 5572, 5573S, 5573, 5574 and 5575 controllers. In December, it will be expanded to include the GuardLogix 5573S and 5572S controllers, which are designed to provide similar automation capabilities as the ControlLogix platform and safety-rated control for safety-related functions.

The controllers are fitted with on-board display features that offer improved diagnostics as well as run-time information to increase uptime and help ease troubleshooting. Its improved security features includes optimized data integrity and quicker data transference with its 1-GB secure digital card.

It will again be expanded in January with the addition of the ControlLogix 5573XT PAC. Suitable for extreme environments and rated for extended temperatures ranging from -25°C to 70°C, this soon-to-be addition is coated for use in corrosive and high-humidity environments.

Rockwell Automation introduces two new programmable logic controllers

Rockwell Automation (www.rockwellautomation.com) has announced the release of its two new Allen-Bradley controllers, the Micro830 and Micro810, as well as the Connected Components software.

A part of the Allen-Bradley Micro800 range, the component-class micro programmable controllers provides machine manufactures a cost-effective control solution, making them suitable for standalone machine applications with less than 48 I/O.

“With this new line, Rockwell Automation is delivering the functionality and flexibility of a micro programmable logic controller for the price of a smart relay. Yet, the greatest value of the new Micro800 range is the simplicity and convenience it provides, with the right amount of control, so customers only pay for what they need,” said Adrian van Wyk, Business Manager at Rockwell Automation.

The Micro800 controllers feature a vast array of plug-in modules for communications, analogue/digital I/O and expanded memory. The range’s plug-in modules allow machine manufacturers to customize the controllers to optimize functionality without increasing the product footprint. Aside form providing removable terminal blocks, the new range also simplifies communication through point-to-point data exchange.

The smallest of the Allen-Bradley Micro800 family, the Micro810 programmable logic controller comes with embedded smart relay function blocks, which can be configured from the keypad and LCD. These function blocks include time of day, delay OFF/ON timer, time of week as well as time of year for applications demanding a programmable lighting and timer control.

Offering flexible communications, the Allen-Bradley Micro830 programmable logic controllers offers up to six high-speed counter inputs. These off-the-shelf controllers have been specifically designed to allow easy integration of up to five plug-in modules on the 48pt variants. They are fully customizable and carry global certifications and support.

Rockwell’s motion-control technology enhances packaging machine

Faced with the challenge of developing machines that produce more products at a faster rate but offer greater accuracy and efficiency, Thiele Technologies (www.thieletech.com) turns to Rockwell Automation (www.rockwellautomation.com) for solutions.

Rockwell Automation provided the control solution that would enhance the flexibility and performance of Thiele’s Nigrelli Envoy Tray Former Packer, a continuous-motion, high-speed packaging system specifically designed for loading cartons, bottles and cans onto corrugated trays, pads or U-board. Processing up to 3,600 containers per minute with exceptionally accurate positioning and versatility, the heart of the Envoy features Rockwell Automation Kinetix Integrated Motion solution that includes an Allen-Bradley ControlLogix controller, Allen-Bradley MP-Series servo motors and Allen-Bradley Kinetix 6000 multi-axis servo drives. Together they control and coordinate all major machine functions, such as placing and carrying the trays through the machine, and control of the rotary tray and feeding system.

Rockwell Automation’s ControlLogix controller eliminates the need for multiple programming packages and controllers, conveniently tying all control functionality into one, multitasking controller platform. Motion functions of the Envoy are incorporated in both the Rockwell Software RSLogix 5000 programming software and the ControlLogix controller. To reduce time spent on wiring, engineers utilized a SERCOS interface module for integration with the Kinetix 6000 servo drives. Operators of the Envoy can view the status and performance parameters of the machine through an Allen-Bradley PanelView Plus 1000 touch-screen human-machine interface.

The RSLogix 5000 software’s motion instructions reduce the need to coordinate and write two programs in separate controllers.

“With the need for high reliability and fast changeovers, the servo control technology from Rockwell Automation provided the best option,” said Stephen Kaye, Rigid Product Line Manager at Thiele Technologies.

Motion over Ethernet provides new level of performance

Rockwell Automation (www.rockwellautomation.com) proudly offers a fully integrated motion solution that operates on similar high-level communications protocol such as those running on other parent automation systems.

With the enhancements on its programmable automation controllers (PACs) portfolio, the company now offers Integrated Motion over EtherNet/IP technology. This new technology helps companies optimize their machine design flexibility, reduce overall system costs and improve their systems performance.

“This really is an important evolution in machine control; what we have done is close the loop,” said Haïthem Mansouri, European Product Manager, Motion Control, Rockwell Automation.

“By introducing motion over EtherNet/IP we have given engineers the ability to side step their reliance on specialist motion protocols, such as SERCOS. This has removed the final remaining barrier that was preventing the adoption of a complete, single, integrated network that is already capable of undertaking safety, process and discrete control.”

“EtherNet/IP is, to all intents and purposes, identical to standard Ethernet; the only change being in the Application Layer,” explained Mansouri. “It uses standard, unmodified Ethernet, and allows users to effectively manage real-time control and information flow for improved plant-wide optimization; ultimately resulting in more informed decision-making and better business performance.”

He added that although other vendors use Ethernet “but they just use the first physical layer – the actual protocol is proprietary and specialist. This means that although they can claim ‘Ethernet compatibility’, it is, in fact, just as closed as any other proprietary protocol.”

With this latest innovation, machine builders can now program, commission, configure and maintain PowerFlex 755 AC drives and Kinetix 6500 servo drives with the outstanding processing capabilities of Allen-Bradley ControlLogix 557X PACs – all over EtherNet/IP.

Rockwell’s new component servo drive

Rockwell Automation (www.rockwellautomation.com) is proud to announce the release of its component servo drive that avoids the complexity of traditional servos. Capable of delivering an instantaneous torque of up to 12.55Nm and available from 50W to 1.5kW, the Allen-Bradley Kinetix 3 allows axes to be tailored to the actual power requirements of a machine, thus lowering costs and system size.

“Manufacturers are challenged by tougher economic conditions. There is less capital available for new equipment purchases and users expect solutions that are easier to use and also yield greater uptime and return on investment,” said Oliver Haya, product manager of Rockwell. “When combining the new Kinetix 3 servo drive with Allen-Bradley MicroLogix controllers, machine-builders can deliver a cost-effective motion control solution for low-axis count applications, that is simple to use and maintain.”

The servo drive is configured with the Allen-Bradley UltraWare software. Configuration can be made easy by using the automatic motor recognition facilities in Allen-Bradley linear and rotary servo motors. More features include advanced auto-tuning, online vibration suppression, as well as rapid settling time, which cut start-ups by eliminating many steps during the commissioning process. The drive can also index up to 64 points through its digital inputs or via Modbus.

Connected Component Building Blocks technology from Rockwell are used to provide CAD drawings, bills of materials, sample code, operator interface screens and electrical layouts for the drive. Indexing operations for three axes are performed on the Modbus network using Rockwell MicroLogix 1400 controller, TL-Series motors, and Allen-Bradley PanelView component operator interface.

Molex introduces Brad SST PB3 Remote Module for PROFIBUS connectivity

Molex Incorporated (www.molex.com) is proud to launch its all-new Brad SST PB3 Remote Module for PROFIBUS connectivity, which was displayed at the Molex booth 1028 during the Automation Fair last November 3. The stand-alone hardware platform includes Ethernet and PROFIBUS communication ports that enable easy and fast connectivity to any CompactLogix and ControlLogix controller from Rockwell (www.rockwellautomation.com). The module will be released in Q2 CY2011 and feature a one-of-a-kind remote design, allowing the PB3 module to be installed next to the PROFIBUS field device. This reduces the expensive cabling costs that happen when the field device and the controller are placed apart from one another.

“The PB3 module provides the same features of an in-chassis module, but is more flexible and easier to use,” said Eric Gory, product manager of Molex. “Its remote design means the PB3 module can be installed in any convenient location such as inside cabinets, on machines or in cells. Additionally, because of its Ethernet media, the PB3 module can be used in specific applications where a wireless connection is needed.”

The PB3 Remote Module is designed for process control, factory automation and machine building applications. The module is integrated into the Rockwell Software Architecture through several features like Ethernet switch with redundancy capability (DLR); “Add-on-Instructions,” which saves integration time; complete access to device diagnostics and PROFIBUS DP-V1 services; and direct access to I/O data without the need to write ladder logic.

Other features include engineering console that runs slave protocols and PROFIBUS master simultaneously and remote diagnostics and configuration through an Ethernet connection for fast commissioning CommDTM driver, allowing Rockwell users in process control industries to do asset management. It also has the ability for multiple types of equipment to connect to one PB3 Remote Module, as well as features easy sharing of I/O process data.

Rockwell’s Ultra 3000 Family

Rockwell Automation, Inc. (www.ab.com) has unveiled the new Ultra3000 family that provides solution through its complete set of servo drives, which range from simple standalone index applications to multi-axis integrated motion. Ranging between 110V and 460V power input, these digital servo drives conform to global voltage requirements and offer flexibility to perform in several machine control architectures. Moreover, the Ultra3000 drive is embedded with ControlLogix platform through SERCOS interface for integrated motion. The integrated Ultra3000i digital servo drive with indexing provides basic stand-alone control capability to the feature set of Ultra3000.

The Ultra3000 family is available from 7.5A to 150A peak current in the 230V platform and 14A to 94A peak current in the 460V platform. Moreover, all power sizes are currently available with indexing. DeviceNet networking and SERCOS interface options.

The Ultra3000 offers simple integration into the Allen-Bradley machine control architectures and accepts step/direction, analog 0V to 10V and master follower command sources, along with DeviceNet connectivity and SERCOS interface across the Ultra3000 family. For multi-axis integrated motion (Kinetix), the SERCOS interface provides integration into the ControlLogix platform. The RSLogix 5000 is the only computer program required for both motion and sequential control. Optimized drive/motor combinations are now available for every application. The Ultra3000 can run several brushless servo motors, such as the Allen-Bradley LD-, Y-, H-, N-, W- and F-series and 1326AB motors with third-party and linear motors.

The Ultra3000 features 100V to 480V AC options, with single and three-phase input. It also has 7.5A to 150A peak current capability, as well as standard D-Shell connectors. It features flash memory firmware storage, seven segment LED, four selectable general purpose outputs and eight selectable general purpose inputs.

A single network from information technology to motion control

Machine builders have achieved new levels of design flexibility through the use of standard Ethernet network platform to easily connect devices across the enterprise and an entire machine, which include variable servo drives and frequency drives for integrated motion control.

The need for different networks to connect devices across an enterprise or set of machines has been long gone as several manufacturers have expanded the use of Ethernet to include most of the applications handled typically by traditional fieldbuses. These changes, which have started with information systems, found a way into I/O control and safety and now have extended to incorporate integrated motion control.

To particularly address the motion control needs, ODVA has added CIP Sync and CIP Motion technologies to the CIP network specification.

CIP Sync is a time synchronization extension to CIP, which is fully compliant with and based on the IEEE-1588 Standard for Precision Clock Synchronization Protocol for Networked Measurement and Control Systems. CIP Sync offers the improved control coordination needed for distributed motion control, demanding events sequencing and other extremely distributed applications where absolute time-synchronization of machines is very important. With the use of this technology, synchronization can be lowered to 100 nanoseconds using unmodified Ethernet hardware.

CIP Motion provides real-time, closed-loop, deterministic motion control over unmodified, standard EtherNet/IP or Ethernet. By adding CIP Sync, multiple axes can now be coordinated for precise and coordinated motion control applications. The use of time-stamped data in CIP Motion, along with its simple timing model, removes the need for any hard synchronization constraints between the controller and the drive.

Based on ODVA’s motion control advancements, new servo drive and VFD solutions can be utilized on machines with single network architecture. For instance, the enhanced Allen-Bradley PowerFlex 755 AC drive and the Allen-Bradley Kinetix 6500 servo drive from Rockwell Automation (www.rockwellautomation.com) provide integrated motion capabilities on EtherNet/IP. These products deliver high-performance, open- and closed-loop drive control that use standard IP and Ethernet technology, allowing manufacturers to unite the two drive technologies on a standard and unmodified network.

Rockwell Automation introduces Modular Servo Drive for enhanced and simplified machine design

Rockwell Automation (www.rockwellautomation.com) is proud to announce its first powerful, modular servo drive, which leverages embedded EtherNet/IP technology for integrated motion control. Its embedded EtherNet/IP drive with Allen-Bradley Kinetix 6500 servo drive will eliminate the need for dedicated motion network, as well as allowing high-performance smart actuators, I/O, drives and other EtherNet/IP-connected devices to be held on a common network. Using it with the Allen-Bradley ControlLogix programmable automation controller (“PAC”), the Kinetix 6500 drive helps to give reduced system cost, improved system performance and increased machine design flexibility.

The EtherNet/IP’s integrated motion within the Kinetix 6500 servo drive utilizes Common Industrial Protocol (“CIP”) Motion, an extension of CIP from the Open Device Vendors Association (“ODVA”). EtherNet/IP is the leading industrial Ethernet topology in the world, with more than 850 product lines in 250 companies and more than two million nodes sold.

Torque, speed and position loops can be adjusted within the Kinetix 6500 servo drive, giving an open, bandwidth solution for motion control. Adding the power of CIP Sync technology from ODVA (“IEEE-1588 compliant Precision Clock Synchronization”) and a variety of axes can be organized for synchronized motion control.

To leverage the tested performance of the Kinetix 6000 family, Kinetix 6500 drive also gives advance safety features, including safe maximum acceleration monitoring, safe direction monitoring, zero speed monitoring and safe stop. These amazing features will improve user safety and enhance machine efficiency by permitting access to guarded areas when a process or machine is still operating, to reduce downtime.

The Kinetix 6500 servo drives have an innovative modular structure to give an adaptable platform for machine enhancements, including increased power range. With interchangeable control modules, one axis can easily transit to another safety functionality or network, to help operators adapt new technologies or market trends, reducing upgrade costs by 50%.

The Kinetix 6500 servo drive is best suited for motion control applications where safety, efficiency and performance are crucial, such as printing and web, packaging, food processing, and other machine types that require position control.

The new Mid-range PACs integrated motion and safety by Rockwell Automation

Rockwell Automation (www.rockwellautomation.com) is proud to announce their latest two mid-range controllers which integrate drive control, discrete, motion and safety capabilities in a single device. The L45S Compact GuardLogix and Allen-Bradley L43S programmable automation controllers (“PACs”) offer functions that are previously available only on Rockwell`s larger Allen-Bradley ControlLogix. These include information and diagnostics capabilities, which help reduce prolonged restarts and nuisance shutdowns, as well as one programming environment.

The new controllers use the same visualization, networking and configuration environment as Rockwell’s larger systems. It helps end-users and machine builders to integrate safety or machine applications cost-effectively to plantwide control systems.

Ken Deken, vice president for portfolio management of Rockwell, predicts that the two controllers will “open a new door for many manufacturers with mid-range applications who previously did not have the means to implement an integrated architecture. The scalability of the Integrated Architecture system means that manufacturers and machine builders can design their applications using a single control engine and a single development environment, regardless of the application size.”

By using Sercos communications, PACs can control approximately eight axes. When utilized with Allen-Bradley Kinetix 6200 servo drives, the controllers give machine builders advanced safety options such as safe direction and safe speed.

Also, the controllers support the use of Point Guard I/O modules and CompactBlock Guard I/O modules from Allen-Bradley on EtherNet/IP, enabling improved sharing and fast system configuration of information. The controllers have highest level of machine safety rating, up to SIL 3 and PL e.

When utilized with new RSLogix 5000 programming software from Rockwell, the latest PACs can utilize high-integrity add-on instructions (“AOIs”) for faster commissioning. The AOIs encapsulate code for usual routines to pre-validated modules, which can be easily reused to help lower risk of coding errors and save time. Manufacturers in regulated sectors, including food and beverage manufacturing and pharmaceuticals, can utilize the software to help protect intellectual property, fulfill regulatory requirements, and manage revision control.

Single development environment with complete functionality across multi-disciplined control systems from Rockwell Automation

Rockwell Automation (www.rockwellautomation.com) has added over 30 new capabilities to its RSLogix 5000 configuration and design software to give users complete functionality for multi-disciplined control systems. With new features, including high-integrity add-on instructions (“AOIs”) and integrated motion on EtherNet/IP, the RSLogix 5000 can help manufacturers save engineering time and give them a higher level of design flexibility.

For the first time, manufacturers can access all the benefits and features of an integrated motion solution using the latest version of the RSLogix 5000 software for maintaining, commissioning, programming and configuring high-performance drives, smart actuators, I/O and other devices in one EtherNet/IP network. Manufacturers should avoid using dedicated motion network to enjoy the simplified synchronization of drives and controllers and help them lower system costs to improved system performance.

The RSLogix 5000 now have new AOIs for safety and standard controllers. Machine users can use it to help maintain instruction and consistency definition revision control, protect their intellectual property, and fulfill regulatory requirements.

By allowing “one to one” transmission of EtherNet/IP I/O data, RSLogix 5000’s Users can now reduce inefficiencies in IT and networking requirements. Moreover, tag communications consumed and produced by EtherNet/IP can span multiple subnets.

The updated RSLogix 5000 help machine users avoid potential harm to products, processes or machinery by protecting it against inadvertent data changes. Also, new capabilities speed up and simplify HMI creation by reducing the number of visible tags while browsing it from the HMI development environment.

One of the key enhancements of the RSLogix 5000 is the DF1 radio modem protocol broadcast support for reducing power consumption and support for other new Rockwell Automation products. Examples of these new products are the Allen-Bradley ArmorPOINT sequence of events module, the Allen-Bradley Kinetix 6500 EtherNet/IP servo drive, the Allen-Bradley Compact GuardLogix L43S and L45S PACs, and the Allen-Bradley ControlLogix L73 and L75 programmable automation controllers (“PACs”).

Allen-Bradley PowerFlex 753 AC Drive from Rockwell Automation

MILWAUKEE, WI — The new Allen-Bradley PowerFlex 753 AC drive from Rockwell Automation provides machine builders and manufacturers with the versatile motor control they need for general-purpose applications. Designed to meet global user needs, the drive supports multiple languages and complies with global standards and certifications. The second release in the PowerFlex 750 series, the PowerFlex 753 drive is suited for many industries and applications, including fans, pumps and conveyors.

Like the PowerFlex 755 AC drive, the PowerFlex 753 AC drive offers many control hardware options. The DeviceLogix control technology helps meet requirements for stand-alone applications by giving users control flexibility to combine inputs and/or outputs, as well as local logic functions, to determine the drive’s behavior. The drive also helps manufacturers minimize downtime because users can configure the drive to provide advanced notification of operating data on cooling fans, I/O relay cycles, motor run-time hours and potential fault warnings. Additionally, Embedded Safe Torque-Off and Safe-Speed Monitoring options help customers reduce overall system costs while helping to protect personnel and equipment, and improve productivity.

Engineers designed the PowerFlex 750 series with a slot-based mechanical architecture that allows customers to tailor the drive with as few or as many options – such as I/O, feedback, safety and communications– as their application requires. The PowerFlex 753 and PowerFlex 755 drives share these hardware options, which help customers reduce inventory. The PowerFlex 753 drive is available in power ranges from 0.75 to 250 kW or 1 to 350 Hp at 400/480V AC and 540/650V DC input.

Rockwell Automation, Inc.
www.ab.com/drives/powerflex/755

Rockwell Launches the New Allen-Bradley PowerFlex 755 AC Drive

MILWAUKEE, WI — Representing the first drive from the new Allen-Bradley PowerFlex 750 series, the PowerFlex 755 AC drive meets global user needs for versatile motor control, integration ease and high performance to help increase productivity. Available in power ranges from 7.5 to 250 kW or 10 to 350 hp at 400/480V AC and 540/650V DC input, the PowerFlex 755 AC drive supports multiple languages, meets global standards and certifications, and is suited for many industries, including converting, automotive, machinery, food and beverage, material handling, metals, mining, and tire and rubber.

The PowerFlex 755 AC drive offers customers more versatility than any other drive in its class in terms of motor control and supporting control hardware options. Examples include:

•To adapt drive control to specific application requirements, engineers embedded Allen-Bradley
DeviceLogix control in the drive. This can give users control flexibility to combine inputs and/or
outputs and local logic functions to determine the drive’s behavior.
•To enable data-driven decisions, embedded Ethernet allows users to easily configure, control and
collect drive data over EtherNet/IP networks.
•To minimize downtime, users can configure the drive to provide advanced notification of operating
data on cooling fans, I/O relay cycles, motor run-time hours and potential fault warnings.
•Embedded Safe Torque-Off and Safe-Speed Monitoring safety options help customers reduce
overall system costs while helping to protect personnel and equipment, and improve productivity.

Engineers designed the PowerFlex 755 AC drive with a slot-based mechanical architecture that allows customers to tailor the drive with as few or as many options – I/O, feedback, safety, communications and auxiliary control power – as their application requires.

www.rockwellautomation.com