Revere Electric

The U.S. Cloud Computing Market: An In-Depth Exploration of its Explosive Growth and Future

2026-01-27T05:41:55+00:00

The U.S. Cloud Computing Market: An In-Depth Exploration of its Explosive Growth and Future

The landscape of technology is constantly evolving, and at its forefront, the U.S. cloud computing market stands as a testament to innovation and rapid expansion. What began as a niche solution for data storage and processing has blossomed into a foundational pillar of modern business and digital infrastructure. Valued at approximately USD 216.91 billion in 2023, the market is on a steep upward trajectory. Projections from various industry analyses paint a compelling picture of future growth, with some forecasting a market size of USD 540.02 billion by 2030, and even more ambitious estimates reaching USD 3,501.32 billion by 2032, exhibiting a staggering Compound Annual Growth Rate (CAGR) of 36.25% from 2025-2032. This in-depth article will explore the multifaceted drivers behind this robust growth, focusing on digital transformation, the relentless rise of Software-as-a-Service (SaaS), and the critical imperative for secure cloud solutions.

Digital Transformation: The Unifying Force

Digital transformation is not merely a buzzword; it is a fundamental paradigm shift that is reshaping industries across the globe, and the U.S. is at its epicenter. Cloud computing serves as the indispensable engine powering this transformation. Organizations are increasingly migrating away from traditional, on-premise IT infrastructures to embrace the agility, scalability, and cost-efficiency offered by cloud-based solutions. This transition enables businesses to deploy new services faster, automate software updates seamlessly, and leverage advanced data analytics to gain deeper insights. The cloud facilitates the integration of cutting-edge technologies such as Artificial Intelligence (AI), Machine Learning (ML), 5G, and the Internet of Things (IoT), which are crucial for delivering real-time user experiences and fostering innovation. By converting large capital expenditures on IT into a more flexible, pay-as-you-go service model, cloud computing significantly reduces the financial risk associated with experimenting with new digital business approaches. The U.S. digital transformation market itself is expected to reach US$1.4 trillion by 2033, growing at a CAGR of 21.6%, a testament to the symbiotic relationship between digital evolution and cloud adoption.

The Pervasive Influence of Software-as-a-Service (SaaS)

Within the expansive realm of cloud computing, Software-as-a-Service (SaaS) has emerged as a dominant and continually expanding segment. In 2023, SaaS commanded the largest revenue share, estimated at a remarkable 55.08% of the U.S. cloud computing market. The widespread appeal of SaaS can be attributed to several key factors. Firstly, the sheer diversity of feature-rich solutions available caters to virtually every business need, from customer relationship management (CRM) and enterprise resource planning (ERP) to collaboration tools and marketing automation. Secondly, the inherent remote accessibility of SaaS platforms has been a game-changer, particularly with the global shift towards remote and hybrid work models. This flexibility allows teams to collaborate seamlessly from anywhere, fostering productivity and efficiency. Finally, the flexible "pay-as-you-go" pricing model of SaaS eliminates the need for hefty upfront investments in software licenses and infrastructure, making advanced tools accessible to businesses of all sizes. Globally, the SaaS market is projected to expand by approximately 20% annually, potentially reaching nearly $1.1 trillion by 2032, with Goldman Sachs forecasting SaaS to constitute 41% of the overall cloud market by 2030, representing a staggering $780 billion.

The Imperative of Robust and Intelligent Secure Cloud Solutions

As the adoption of cloud computing intensifies, so too does the criticality of robust security measures. The increasing sophistication and frequency of cyber threats, including data breaches, ransomware attacks, and phishing schemes, have made cloud security a paramount concern for businesses. This heightened awareness, coupled with stringent regulatory requirements such as GDPR and CCPA, compels organizations to implement advanced security protocols to safeguard sensitive data and ensure compliance. The U.S. cloud security market is projected for substantial growth, with estimates indicating an expansion from USD 10.0 billion in 2025 to USD 31.2 billion by 2033, at a CAGR of 14.2%. Other reports suggest the U.S. cloud security software market could reach USD 72.5 billion by 2032, with an 18.1% CAGR from 2025. The global cloud security market is also expected to reach around USD 100.07 billion by 2032, growing at a CAGR of approximately 14.20%.

Several factors contribute to this escalating demand for secure cloud solutions:

Rising Cyber Threats: The ever-evolving threat landscape necessitates continuous innovation in security measures to protect against increasingly sophisticated attacks.
Regulatory Compliance: Adherence to data privacy regulations is not optional; it's a legal and ethical imperative that drives investment in advanced security and compliance tools.
Remote and Hybrid Work Models: The distributed nature of modern workforces amplifies the need for secure access to cloud resources and comprehensive data protection strategies across diverse endpoints.
Multi-Cloud Environments: As businesses adopt hybrid and multi-cloud strategies, the complexity of managing security across disparate platforms increases, driving demand for unified security solutions.
Technological Advancements in Security: The integration of Artificial Intelligence (AI) and Machine Learning (ML) into cloud security is revolutionizing threat detection, enabling predictive analytics, and accelerating incident response times, making security more proactive and efficient.

The Future is Cloud-Native

In conclusion, the U.S. cloud computing market is not just experiencing growth; it is undergoing a profound transformation that will redefine the future of business and technology. The relentless march of digital transformation, the pervasive adoption of SaaS, and the unwavering commitment to robust and intelligent secure cloud solutions are the primary engines driving this expansion. As businesses continue to embrace cloud-native strategies and new technological innovations emerge, the cloud will remain the foundational pillar of the digital economy, fostering unprecedented innovation, efficiency, and resilience for years to come. The journey towards a multi-trillion dollar cloud market is well underway, promising a future where cloud computing is not just an option, but an absolute necessity for success.

Trustworthy AI: Federal Executive Orders

2026-01-22T09:01:53+00:00

Executive Orders: Paving the Way for Trustworthy AI in the Federal Government

The rapid advancement of Artificial Intelligence (AI) presents both immense opportunities and significant challenges. Recognizing its transformative potential, the United States federal government has proactively issued a series of Executive Orders aimed at ensuring the responsible, secure, and trustworthy development and deployment of AI within its agencies and across the nation.

Key Executive Orders and Their Impact

Executive Order 13960: Promoting Trustworthy AI in the Federal Government (2020)

Issued on December 3, 2020, Executive Order 13960 provided crucial guidance for federal agencies on adopting AI to enhance service delivery and build public confidence. This order established core principles for AI use in government, mandated agencies to catalog their AI use cases, and directed the General Services Administration (GSA) and the Office of Personnel Management (OPM) to bolster AI implementation expertise within federal entities. Its focus was on creating a common policy framework for ethical and effective AI integration.

Executive Order on the Safe, Secure, and Trustworthy Development and Use of Artificial Intelligence (2023)

A more comprehensive directive, this Executive Order from October 30, 2023, underscores the importance of balancing AI's benefits with potential risks such as bias, discrimination, and security vulnerabilities. It laid out policies to advance AI safety, encourage innovation, safeguard civil rights, and strengthen national security. A particular emphasis was placed on mitigating risks to critical infrastructure, cybersecurity, and preventing the misuse of AI in harmful applications.

Executive Order 14179: Removing Barriers to American Leadership in AI (2025)

Looking ahead, Executive Order 14179, dated January 23, 2025, aims to dismantle obstacles hindering U.S. leadership in AI. This order seeks to encourage the widespread adoption of AI applications across various sectors, fostering an environment conducive to American innovation and competitiveness in the global AI landscape.

Executive Order: Ensuring a National Policy Framework for AI (2025)

Building upon the foundation of EO 14179, this Executive Order from December 11, 2025, strives to establish a uniform federal policy framework for AI. It explicitly aims to remove barriers to U.S. AI leadership, emphasizing that a strong American presence in AI will bolster both national and economic security. This order also includes a legislative recommendation for a consistent federal AI policy that would preempt conflicting state AI laws, with certain exceptions.

Laying the Groundwork: Earlier Initiatives

Executive Order 13859: Maintaining American Leadership in AI (2019)

The journey towards trustworthy AI began earlier with Executive Order 13859, issued on February 11, 2019. This order established the American AI Initiative, outlining key areas of focus including increasing AI research investment, leveraging federal AI computing and data resources, setting AI technical standards, developing the AI workforce, and fostering international collaboration.

Executive Order 14320: Promoting the Export of American AI Technology Stack

Further reinforcing the U.S.'s commitment to global AI leadership, Executive Order 14320 focuses on ensuring that U.S. AI technologies, standards, and governance models are adopted internationally. This initiative aims to strengthen alliances and maintain technological dominance in the rapidly evolving field of AI.

The Path Forward

These Executive Orders collectively demonstrate the federal government's commitment to harnessing the power of AI responsibly. By establishing clear principles, promoting innovation, and addressing potential risks, these directives are crucial in building public trust and ensuring that AI serves the best interests of the nation.

The Rise of AI-First Cloud Platforms

2026-01-21T12:37:56+00:00

The Rise of AI-First Cloud Platforms

Artificial intelligence (AI) has transcended its role as a mere workload in the cloud, evolving into a foundational element embedded within core cloud services. This profound shift is redefining how organizations leverage cloud computing, ushering in an era of AI-First Cloud Platforms where intelligence is woven into the very fabric of infrastructure management, security monitoring, application development, and analytics.

AI as an Integral Cloud Component

The integration of AI into cloud services is enabling unprecedented levels of automated decision-making and predictive system behavior. Imagine cloud environments that can anticipate resource needs, proactively identify security threats, and optimize application performance without human intervention. This is the promise of AI-First Cloud Platforms, where AI capabilities are not just add-ons but fundamental drivers of efficiency and innovation.

Key Trends Shaping the AI-First Cloud Landscape

Several key trends are accelerating the adoption and evolution of AI-First Cloud Platforms:

AI-as-a-Service (AIaaS) and Generative AI: The growth of AIaaS allows businesses to access pre-built AI models and tools, democratizing AI implementation. Generative AI (GenAI) is a significant catalyst, with cloud providers heavily investing in and delivering GenAI solutions. Platforms like Amazon Bedrock exemplify this trend, offering user-friendly interfaces for customized generative AI models.
Hybrid and Multi-Cloud Strategies: Organizations are increasingly adopting hybrid and multi-cloud approaches to manage AI workloads, ensuring flexibility, redundancy, and vendor-agnostic solutions. This allows for seamless movement of AI processes between edge, on-premise, and multiple cloud environments.
Data Modernization and AI-Powered Architectures: Data is the lifeblood of AI. Companies are focusing on AI-ready data platforms and robust data governance to effectively leverage AI, especially generative AI, and unlock new value from their data.
Edge AI Computing: Deploying AI at the edge reduces latency and enables real-time analysis and decision-making. Advancements in 5G networks and energy-efficient processors are making edge AI increasingly viable for diverse applications.
Security, Ethics, and Data Sovereignty: As AI adoption grows, robust security measures, including AI-powered threat detection and zero-trust security, are paramount. Ethical AI considerations and data sovereignty requirements are also driving the development of responsible AI practices.
Automation and Serverless Computing: Automation and serverless computing are gaining traction due to their cost efficiency, scalability, and ability to abstract away server infrastructure management, allowing developers to focus on application logic.
Sustainable AI: There's a growing emphasis on developing and deploying AI systems with minimal environmental impact, prioritizing energy efficiency in design and operations.

Optimizing AI-Centric Cloud Investments

Organizations are keenly focused on optimizing their AI-centric cloud investments. This includes:

Efficient GPU and AI Accelerator Hardware Utilization: Maximizing the performance and cost-effectiveness of specialized hardware designed for AI workloads.
Redesigning AI Models for Efficiency: Developing AI models that are not only powerful but also resource-efficient, reducing computational overhead.
Moving AI Inference to the Edge: Shifting AI processing closer to data sources to reduce latency and enable real-time insights.

The Future is AI-First

Cloud providers like AWS, Microsoft Azure, and Google Cloud are expanding their offerings to deeply integrate AI capabilities, providing scalable infrastructure, MLOps services, and specialized tools. This deep integration and the broadening adoption of AI across various industries are transforming cloud computing into an AI-first paradigm, where AI is not just a feature but a fundamental component driving innovation, efficiency, and competitiveness. The future of cloud computing is undeniably intelligent, with AI at its core, enabling businesses to unlock new possibilities and deliver personalized digital experiences.

NSF Launches IDSS Program to Bolster National AI Infrastructure

2025-11-14T11:09:52+00:00

NSF Launches IDSS Program to Bolster National AI Infrastructure

The U.S. National Science Foundation (NSF) has taken a monumental leap forward in advancing artificial intelligence research and development with the introduction of the Integrated Data Systems and Services (IDSS) program. This ambitious initiative is designed to establish a national-scale AI infrastructure, providing the foundational cyberinfrastructure necessary for open, data-intensive, and AI-driven science and engineering.

Goals and Scope of the IDSS Program

The primary objective of the IDSS program is to support national-scale foundational data cyberinfrastructure that empowers data and AI-driven research across a multitude of scientific and engineering communities. Beyond this, the program seeks to connect diverse data sources with advanced computing resources, effectively addressing the complex data-intensive workflows inherent in modern AI research. A key focus is on enabling critical points within the data lifecycle at a national level, ensuring seamless access and utilization of vast datasets.

The scope of IDSS is broad, encompassing national-scale operational systems and services that facilitate open, data-intensive, and AI-driven science and engineering. It actively encourages transdisciplinary projects that promise a wide-ranging impact on the science and engineering research and education community.

Integration and Project Categories

A cornerstone of the IDSS program is its emphasis on integration. It aims to seamlessly blend with existing cyberinfrastructure systems and services, fostering an integrated, federated, and easily accessible advanced research cyberinfrastructure ecosystem. Crucially, systems and services awarded under IDSS will be integrated into the National Artificial Intelligence Research Resource (NAIRR) and other NSF-managed programs, creating a cohesive national AI landscape.

The program invites proposals across three distinct categories:

Category I: Focuses on the development, deployment, and operation of novel national-scale integrated data systems and services.
Category II: Supports the transition of established smaller-scale, regional, pilot, or prototype data-focused systems and services to national-scale production and operational quality. This also includes enhancements and expansions of existing national-scale data-focused operational systems and services.
Category III: Provides planning grants for future potential development, deployment, transition, or enhancement of IDSS projects.

NAIRR Pilot Integration and Future Impact

The IDSS program is a vital component of the White House's AI Action Plan, working towards the overarching goal of establishing a robust national AI research resource. As part of this commitment, the NSF has already selected 10 datasets for integration into the NAIRR Pilot. This pilot serves as a shared national infrastructure, providing critical support to the AI research community and promoting the responsible use of AI technologies.

Through the IDSS program, the NSF is not just expanding infrastructure; it's cultivating an environment where AI innovation can flourish, driving scientific discovery, technological advancement, and educational enrichment for the benefit of the entire nation.

You Bought Rockwell Software, Now What?

2022-09-14T20:35:03+00:00

Learn how to Download, Install and Activate Rockwell Software

How do you install Rockwell software? It is a question we get asked all the time and so we decided to share it in this blog post. If you have further questions, please reach out to··us at customersupport@revereelectric.com.

Download the installation files:

• Go to this link: https://download.rockwellautomation.com/webupdates/enter.aspx

• Enter the serial number and the company name to authorize the download

· If you do not know your serial number, contact us at the email above

• Choose the version of the software you want to download

· If you do not see the version you want to download, then you need to purchase a tech support contract.

• Clicking on the Cart and the download button creates a ‘Download Manager’ in your downloads folder

• Run the download manager

• Once the files are downloaded, they will show up in your C:\RA folder

To install the software:

• Go to the C:\RA folder

• Find the folder for the software that you downloaded. For this example, we will use Studio 5000

• In that folder, find the one named something like this: ‘xx.xx-Studio5000-Web.part1’ and double-click to run it (this will extract all the files)

• Now look for the new folder that was created, it will be named something like ‘xx.xx-Studio5000-Web’, open the folder

• Double-click to Run Setup, follow the prompts

If you have already installed the software and you just need to ACTIVATE it, then proceed as follows:

• Follow this video on how to activate Rockwell software: https://www.youtube.com/watch?v=MAAVLFONNxA

• If you try to follow the video, but you do not know your product key, then you have two options to get this information:

· Option 1, call Rockwell Automation to obtain it: Rockwell’s phone number: 440-646-5800

· Dial Direct Dial Code 010 for the activations group

· Tell them your serial number and company name and ask for the product key

· Option 2, Go to this website to get your activation certificate: https://download.rockwellautomation.com/webupdates/enter.aspx

· Enter the serial number and the company name - If you do not know your serial number, contact us at the email above

• On the next page you should see a tiny PDF icon. Click this to download your activation certificate. If you do not see the PDF icon, click the plus sign on the left to expand and you should see it under there

Side note:

• If you try to follow the video and it says no activations are available, then that means the activation is being used already and you have 2 options:

· Option 1, Find the computer (or dongle) to which the activation is hooked to and “rehost the activation”

· Video on rehosting an activation here: https://www.youtube.com/watch?v=WAFqho1q3Us

· Option 2, If the computer is dead, destroyed, or wiped, then you can call Rockwell to tell them what happened, and they can rehost the license on their end.

· To ask Rockwell to rehost a license for you, call them at 440-646-5800

· Enter 010 for the Direct Dial Code to get to the Activation Group

· Once Rockwell rehosts the license for you, you can follow the video on how to activate the software (above).

PanelView Plus 7 Performance Change to Series B

2022-03-17T15:51:49+00:00

What You Need to Know about the New PanelView Plus 7 Performance, Series B

For many decades the Rockwell Automation PanelView family has been an excellent solution for a Human Machine Interface (HMI) control system. Those experienced in the industry have seen PanelView terminals go through multiple changes and upgrades, each time improving the performance and features. In a continuing effort to increase the usability and support the longevity of the PanelView Plus platform, Rockwell has completed a hardware/software refresh of the PanelView Plus 7 Performance. This refresh is being denoted as a change from Series A to Series B.

The longevity of many automation devices comes down to the ability to source the hardware components and support the software running on them.The Series A PanelView Plus 7 performance runs Windows CE 6.0 which is no longer fully supported by Microsoft. The terminals also use aging hardware with a shrinking supply chain. The new Series B has updated hardware with improved availability and long-term supply chain support. Running on the new hardware is a new operating system, as the Series B runs Windows 10 IoT Core. These changes will increase the feature set and usability of the PanelView terminals while also improving delivery time. This revision also shows a commitment that the tried-and-true PanelView HMI will continue to improve and be around for many years to come.

From a development standpoint there are no changes as the terminals still utilize FactoryTalk View Studio ME.The Series B units will continue to run applications developed on a Series A without modifications. Here is a list of items that also stay consistent with Series A terminals.

• Certifications
• Panel cutouts
• Accessories
• Catalog numbers
• List Prices

As for improvements, there are a few that stand out to us. First, is that user storage has been increased significantly from 80MB to 2GB. Anyone who has tried to load multiple copies of a large application onto one PanelView has felt the pain of running out of storage. Second, is the addition of a hardware maintenance mode button. In the past to enter this mode you had to cycle power to the terminal, press the corner of the screen, and hope you could find a USB keyboard as it was the only way to navigate those settings. Now features such as factory reset and device cloning can be reached with the simple press of a button and use of the touch screen. Third, is that the new Series B uses ControlFlash Plus for firmware updates. Now the same feature packed, User-friendly software that you use to update your other control products can be used to update the PanelView Plus. Below is a complete list of Series B improvements:

• Enhanced product security
• Support for modern peripherals
• Intel x86, 1.46 GHz, dual core processor
• Significantly increased user storage (from 80meg to ~2GB)
• Firmware update process is consistent with other Rockwell products (ControlFlash Plus)
• Microsoft Edge Web browser , HTML5 compatible (when available)
• Hardware button to restore terminal to factory default condition

Another thing to note, with cybersecurity quickly becoming an increased point of focus for manufacturing networks, the transition to Series B has a focus on security. The new operating system has allowed many new security features to be built into the core of the PanelView and new features will continue to be added as updates roll out for the operating system. Here are a few of the security features of the Series B terminals.

As the PanelView Plus 7 Series B has been brought to market to help alleviate the production restrictions on the Series A, there are some features that will not be present upon initial release. Please note the features below that are not present in initial Series B release. These features will be added with incremental firmware updates over the next 3-12 months.

While Rockwell Automation series information is noted on packaging labels, it is not always easy to quickly spot and identify. Because of this, Rockwell is placing a large sticker on the Series B packaging - right where the box would be opened - to make sure the user knows they are receiving a Series B unit. That sticker will have a QR code linking to a website to explain the feature differences between Series A and Series B. Since this is a link to an active page, that page will be updated as the originally omitted features become available.

The Series B units are shipping now. If you have existing orders for PanelView Plus 7 Performance models, chances are they will be fulfilled with Series B terminals. If your application still requires any of the missing features, Series A units can still be obtained, but only for a limited time. Do not open the Series B package unless you are sure if will work for your application.

Please reach out to your Revere Account Manager for more information or contact us at customersupport@revereelectric.com.

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Rockwell Automation Introduces the Kinetix 5300

2021-04-15T18:44:37+00:00

Kinetix 5300 Motion Control Solution for Smart Machines

Have you ever needed a single axis of motion that also needed to seamlessly integrate with your PLC? If so, Rockwell Automation’s Kinetix 5300 is the perfect solution. The Kinetix 5300 is an entry level CIP motion, single axis motion solution. This servo drive utilizes add on profiles (AOP’s) with a motion ready automation controller to integrate into your Studio 5000 project.

One thing to note, the Kinetix 5300 serves as a replacement for the Ultra3000 sercos drives, the Kinetix 2000 and the Kinetix 350; allowing customers a simplified migration path. The new Kinetix 5300 product line, combined with the rest of the Kinetix family, provides a complete range of servo drive offerings from small, standalone machines to large, complex systems.

The Kinetix 5300 is available in 120V/230V single phase up to 2KW and 230V/480V three phase up to 7.5KW. The Kinetix 5300 supports the TLP as well as the MPL series of motors (depending on feedback type, resolver not directly supported). Paring the Kinetix 5300 with a TLP motor is a cost-effective way to add motion to any application. The Kinetix 5300 has dual ethernet ports (with DLR) and hardwired safe torque off (STO).

The Kinetix TLP motor offers a wide-range system power ratings solution for a variety of motion control applications. Combining the TLP, The Kinetix 5300 and matching 2090-CT servo cables creates a validated system. Also, the TLP and cable combination provides flexibility with many built-in options. TLP is the next generation of TL and TLY motor - with a similar flange size and wider power range. You could easily swap the existing TL and TLY without dramatically changing the machine construction.

Did you know that Revere offers a complete mechatronic solution which includes actuators, gearboxes, couplings, motors, cables and robotics? Interested in learning how the Revere motion team can properly equip your next machine application? Whatever your motion needs, you can count on Revere’s Motion team to provide the right equipment for your machine. Reach out to your Revere account manager for more information.

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Automation Fair At Home Daily Debrief

2020-11-16T20:26:08+00:00

Revere Electric Supply | Automation Fair At Home | Daily Debrief

2020 has certainly been an interesting year. Due to the COVID-19 outbreak, we have all changed the way in which we work, interact, and connect. With that mindset, Rockwell Automation decided to take this opportunity to bring us their largest trade show event, Automation Fair, in a dynamic virtual platform. This week Automation Fair at Home is happening live. We encourage you to register for the event and take part in the experience. If you can’t attend this week, don’t worry, the sessions and experiences will be available until the end of June, but you will need to register to gain access. Register now. Still wondering if Automation Fair at Home is worth attending? To help you decide, below is a daily recap of what our sales and automation team took out of the event. Hopefully it will inspire you to participate in this momentous event.

Day One Debrief | November 16, 2020

The DX series on Digital Transformationis about bringing the right people from Rockwell Automation, Microsoft, ANSYS and PTC together to offer their unique perspectives.

PT71 Reduce Costly Downtime Using Hubbell’s Intelligent Electrical Monitoring Devices: Key Takeaway, It’s more than just wiring devices. Great solution for a critical area that needs remote monitoring that can be tied into your automation system, wirelessly. Excellent application for critical cold storage & climate control (Food & Beverage and Pharma).

PT74 - Strike Back Against Electrical Shock with Prevention through Design:Key takeaway, per the statistics, 70% of users experience some sort of electrical shock on industrial equipment 220Vac and above.

PT18 - North America Standards Update: Applying Standards Changes to Allen-Bradley® Products:Key Takeaways: Update to NFPA79 available in November. Requirements for Fault Current documentation NEC2017 Article 110.24. NEC2020 article 409 Industrial Control Panels need to be marked for AFC (Available Fault Current)
- NEC2017 Article 670 AFC (Available Fault Current) documentation requirement AFC not to exceed SCCR of panel
- NEC2017 Article 430 VFD sizing of branch circuit protection devices
- NEC2017 Article 240 Arc Energy Reduction >1200 amps
- NEC2017 Article 670.6 Surge Protection & Safety Interlocks / Updated in NEC2020
- NFPA79 Section 7.8 TVSS protection Safety Circuits
- UL508A Supplement B Changes: SCCR BusBar, Table for 3 Phase transformers updated, SCCR requirements for new components & SCCR component exceptions

PT17 - Short-Circuit Current Ratings and Your Panel:Key Takeaway, SCCR value must be documented. Highly suggested for any customer building control panels.

PT73 – Reduce Unplanned Downtime and Endorse Predictive Maintenance:Key Takeaway, this seminar didn’t discuss a solution or platform for predictive maintenance but rather shows the costs of downtime to end users, types or maintenance used by end users, and the impact of Covid and the need for remote support to continue keeping a plant running.

Benefit:This session is relatively short (about 30 minutes) and really helps give viewers greater insight into the huge risk they face with downtime. Average costs for downtime are $260,000 per hour, with certain industries such as auto and gas/oil running in the hundreds of thousands per minute! Even more important than economical cost is the lives that are at risk while performing maintenance. The speaker goes into types of maintenance and ultimately provides pros/cons for each type. Biggest take away is the push for smart machines and use of IoT and smart sensors to change our mindset on how we go about setting a maintenance plan at a facility.

DX0 – Digital Co-innovation Brings the Connected Enterprise to Life:Key Takeaway: Rockwell Automation is co-innovating with our partner ecosystem of digital leaders to help bring the connected enterprise to life with best-of-breed solutions that connect critical business functions. Some topics of discussion were about best practices on implementing a digital thread strategy enabled by advanced digital capabilities; such as browser-based CAD, 3D emulation, physics-based digital twins, and cloud to deliver exciting new capabilities for collaborative design, preventive maintenance, and real-time visibility.

It’s interesting to acknowledge that we can’t make this digital transformation alone, nor are we alone in this journey. Rockwell Automation is establishing partnerships with leading edge companies. Revere Electric plays a critical role in this process, to understand our Customer’s needs “today” while sharing critical information with customers that will make them stronger in the marketplace. It’s exciting to see the partnerships that Rockwell has developed with companies like Microsoft, Emulate 3D and others, all of which collaborated during this seminar.

The Smart Motor Control session in the Rockwell Product and Technology Showcaseprovided a great simulated hands-on explanation for the three newest functions in drive technology: Automatic Device Configuration for truly plug and play drive mechanical replacement with NO configuration required, Functional Safety for all the various safety functions available including network coordinated safety, and Coordinated Machine for fractional HP servo motors to multi-hundred HP induction motors coordinated and synchronized motion control to optimized production. There are the new technologies that support the higher production rates required today with less downtime.

Day Two Debrief | November 17, 2020

Leadership During the Time of the Pandemic: Key Takeaway, this session was a panel discussion covering changes and challenges they have faced as leaders over the past few months with shutdowns and more employees working from home. It was interesting to hear the acknowledgement that many of the former stigmas of working from home have been proven wrong and that a “new normal” of remote working and interactions will remain for the foreseeable future. With that, it’s important to learn how to operate and take advantage of the new conditions, because will be very important moving forward.

PT61 – Leveraging Technology to Monitor Power Quality and Motor Protection: Key Takeaway, this technology session gave some vendor-specific (in this case, TCI) solutions to solve power quality issues between the variable frequency drive and the motor. The session gave good guidance about if and when to use three levels of technology that they offer. It started with an overview of VFD technology (how VFDs work), then it moved on and gave reasons why there may be power quality/noise issues and reasons why mitigating those issues is a good idea for our customers. The session wrapped up with a software/add-on technology that they offer to monitor power quality events in real time for use with preventive maintenance and to avoid downtime.

DX07 - Understand the Value of PLM in Your Digital Transformation: Key takeaway, This session was a customer (Fresenius Medical Devices) talking through their PLM/PDM transformation. I learned that there isn’t really a plug & play PLM solution. In this particular case, it’s an ongoing multi-year effort seemingly touching every part of the organization. It’s crucial to have agreed upon ROI and KPI measures over the span of the effort.

Our Motion, Drives and Motors Business Lead went through all the different Engineering Halls and really enjoyed seeing the digital twin technology in Engineering Hall 1. He stated, “It really showed off all of Rockwell’s design tools using 3D emulate and digital twin technology. Showing how quickly a customer can rapidly deploy automation”.

PT09 – Mechantronics: Help Reduce Design Time and Commissioning Risk: Key takeaway, This session went through all the different mechatronic design tools that are available; one in particular, motion analyzer, allows secure and scalable control aspects of logix and studio 5000 platform. Robotics was also discussed and detailed how Rockwell Automation controls can integrate easily with several robotic manufacturers. Finally, they discussed the transport piece with the icart technology.

PT16 - Understanding Arc Flash Hazards, Solutions and Standards: Still confused by Arc Flash? IL Industrial Control Product Specialists, Dan Pierce, personally suggests taking the time to sit in on this session. Statistics are “shocking”! Key takeaways: 1) Understand the 4 primary standards that drive arc flash protection & compliance in the United States. 2) Quick overview of what is coming in 2021 in regard to NFPA70E.3) Uncover the "how-to" of implementing arc-resistant equipment within typical industrial or commercial facilities. This workshop offers insight into several practical aspects of procuring and applying arc-resistant equipment including NFPA 70E highlights, arc flash basics and a review of arc-resistant equipment including the PowerFlex®7000 AC drive.

REALLY … a single session that provides the complete picture of how the products and technology presented in this Rockwell Automation Fair tie together to benefit us. For a look at how to simplify your next engineering project visit the Rockwell Product and Technology Showcase > Digital Engineering Hall > “End to End Demo of a Digital Engineering Project”. This session shows you step by step how you drastically reduce engineering time by using reusable machine components with their “associated” and already tested modular PLC/HMI code, together with simultaneous collaborative engineering to build the complete machine. And the final step is virtual commissioning thru the most complete simulation capability available today.

Jim Armstrong, Automation Manager in WI, spent some time today at the EPLAN booth, located in the Expo Showcase -> Partner Showcase -> Software Technology. EPLAN offers software and services in fields of electrical, automation and mechatronic engineering, also known as CAE - Computer Aided Engineering, for machine, plant and control cabinet engineering. The EPLAN Platform includes products that are tailored to provide efficiencies in design and engineering of electrical and automation projects. EPLAN is a Digital Partner with Rockwell-Automation, and there was a nice video that explains that partnership. This software leverages Rockwell-Automation components through the Data Portal, while also providing efficiencies in Schematic Design and Logix Programming through the integration if IAB and Studio 5000 w/ the EPLAN software. There are many other videos and resources available at this Partner site. Check it out.

Day Three Debrief | November 18, 2020

Session: PT42 - Identify, Solve and Help Prevent Industrial Ethernet Cable Problems in Harsh Industrial Environments: Key takeaway, With Ethernet everywhere, it’s great to have access to an A-B solution partner like Fluke. This session really did a deep dive on troubleshooting Ethernet communication problems. The speaker’s command of the subject matter, practical troubleshooting sense and delivery style made this a good watch for anyone needing to get a better handle on plant Ethernet installations and maintenance.

PT19 - Never Miss an Update: Manage Your Enterprise Software/Firmware with Ease: Key takeaways, 1) Product Compatibility and Download Center (PCDC) Subscriptions & Notification - Subscribe to product information & be Notified when changes have occurred about the products that you specify. Also get notifications on new version or series releases, advisories, and lifecycle changes. 2) ControlFLASH Plus v4 - Rapidly deploy changes and manage firmware inventory. 3) FactoryTalk Updater v2 - No more wondering what software you have on various PCs. You can see a list of installed software on each workstation on your network. Information displayed includes software that is installed, version(s) installed, as well as activations. Also, you can collect multiple machine inventories without all individual machines being connected to the internet.

PT23 - Work Smarter, Faster and More Efficient by Employing a Digital Environment: Key takeaways, this session spent some time talking about 3D Emulate and announced the newest line of RS5000 emulation, called FT Logix Echo due in 2021. This was a great session to give a customer an understanding of the basics of Digital Engineering; it covered the “Technologies Enabling Digital Thread” including 3D Emulate, ANSYS and the brand new Factory Talk Logix Echo.

Have you had a chance to visit the Spectrum Controls product booth? Just because we are virtual doesn’t mean that traditions are not going to be honored. Spectrum found a virtual way to take a picture with your friends from the Matrix. All you need to do is upload a selfie to their virtual platform. They also created an escape the Matrix game – basically Pac Man - So fun! And while you are having fun, remember, the Universal Industrial Gateway can speak up to 12 protocols simultaneously, talk to multi-devices at once, move thousands of tags into 1 box, and bridges communication gaps between devices, Ethernet and/or serial. Includes: Modbus, PPI, DirectNET, CCM, HostLink, Ethernet/IP, S7comm, & DF1 protocols. Check out the fun! (https://www.spectrumcontrols.com/matrix/af2020/)

Over the last three days, Rockwell has opened the event with a session called Perspectives. Unfortunately, tomorrow and Friday do not have a Perspective session, but I would highly recommend watching the first three on demand. This morning’s perspective had a special guest, Jason Silva a Venezuelan American filmmaker, philosopher, television personality, and public speaker whose stated goal is to use technology to excite people about science and philosophy. Described as "a Timothy Leary of the viral video age," Silva lectures internationally on such topics as creativity, disruptive technologies, and humanity, writes and produces short films, and co-hosts National Geographic's #1 rated series "Brain Games." He can most recently be seen as the host of the eight-part National Geographic series "Origins: The Journey of Humankind." He spoke to us about expanding human possibilities and expanding human imagination on the back of digital transformation. He speaks very passionately about how our creative minds can become possible through technology. Technology is how we turn the mind inside out – if you imagine it, it will come. Great session – highly recommended.

Day Four Debrief | November 19, 2020

PT32 – Modernization: Improve Your Performance in Established Equipment: Key takeaways, They did a great job laying out how you would go about modernizing equipment to take advantage of the Industry 4.0. From assessing your current situation to planning on how to improve or meet goals and then finally executing based a planned timeline. They also dive into some case studies with a panel of experts discussing safety solutions and performance improvement options to meet goals.

PT32 Modernization: Improve Your Performance in Established Equipment: One of the key takeaways is that people often only associate controls upgrades as a mitigation to risk. Sometimes they view the entire control system as a necessary evil and hope to simply set it and forget it. In reality, moving to a modern control system brings many advantages when the features are properly utilized. These advantages include improved performance, easier supportability, proper cyber security, and advanced safety. On top of that, modern control systems are data capable and allow you to start your Digital Transformation with IoT technologies such as remote access, real time diagnostics, data collecting, and reporting.

DX09 - Get the Most Out of Machine Learning to Boost Industrial Performance; Key takeaways, this was a good overview of the machine learning currently available from RA and its partners; it covers Factory Talk Data Explorer, Factory Talk Analytics Logix AI, Factory Talk Augmenter Modeler and finally PTC’s Analytics Builder.

DX10 - FactoryTalk® InnovationSuite Powered by PTC: Your Key to Industrial Digital Transformation: Key takeaway, This was also a good class that added on to the DX09, but from the PTC point of view.

DX12 - MES: The Heart of Your Digital Transformation: Key Takeaway, a great overview of manufacturing in America and where it is headed, as well as what Smart Manufacturing really means. The seminar then went into the specifics of what is MES (Manufacturing Execution System) software and why it is important in your Digital Transformation.

PT08 - Independent Cart Technology: Key takeaways, this session was phenomenal. It shared market trends, such as the change in consumer demands that manufacture struggle with and the need to keep up with those demands and increase the speed to market. They also showed improved programming through the application code manager (ACM). System layouts for the tracks can be easily imported into emulate 3D along with 3rd party robots integrated with the independent cart technology. Emulate 3D can also output and generate the PLC code and connection.Lastly, they also showed tying into the capabilities with descriptive and prescriptive analytics can be used for preventative maintenance, reduce unscheduled downtimes.

Automation Fair at Home Sessions Are Available to Watch On Demand Until June 2021.

Contact us if you would like more information on attending sessions or if you would like to learn more about a product and/or service that you saw in a session.

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The New Rockwell Automation Kinetix 5100 and TLP Motor

2020-09-25T20:18:53+00:00

Rockwell Launches the Kinetix 5100 and TLP Motor

Have you ever wanted to add a single servo to your system without having to change your control hardware or program? Well, now you can. Rockwell Automation recently launched two new products; the Kinetix 5100 and the TLP Motor. Both products offer a cost-effective solution for your current system(s); whether it’s new or mature.

The Kinetix 5100 is a single axis motion solution. This standalone servo controller does not require a controller to operate, but you can use one if you prefer. It has index capabilities and includes 99 pre-set indexes. The Kinetix 5100 supports 1.5 axis applications for electronic gearing or camming, for standalone rotary knife or flying shear applications. It can follow an Analog input or use Pulse Train Output (PTO). If you need to communicate with the Micro 800 or the Logix series of controllers it can do that by using specially designed AOI’s that will let the device operate the drive over Ethernet. The Kinetix 5100 utilizes free software for setup and initial configuration, which can be found in Rockwell Automation Product Compatibility and Download Center (PCDC).

Additional features of the Kinetix 5100 include:

Safe Torque off (STO)
10 freely assignable inputs
5 freely assignable outputs, which can be switched back and forth as needed (i.e. speed to torque)
Aux Feedback port, allowing ½ axis support or dual loop control functionality
Electronic Camming (720 Points max)
Gearing (Master and Slave)

Right now, the Kinetix 5100 is available in 120V and 230V single phase up to 2KW and 230V three phase products up to 15KW. The 480V three phase versions are scheduled to come out in the fall of 2020. As far as motors are concerned, the Kinetix 5100 supports the new TLP, as well as the MPL series of motors (depending on feedback type, resolver not directly supported).

Now here is some information about the new TLP motor. The TLP motor is the first motor to use the JIS Standard for motors. Having this standard means that if you need to retrofit similar products from Asia or other countries, it will be seamless, and you won’t have to worry about previous challenges like different shaft sizes and pilots. The TLP Motor also allows you to customize your machine with eight (8) available frame sizes, with power ranges from 50W to 15KW. They all have 24-bit Absolute feedback (required external battery to maintain position), and an available 24Vdc holding brake. The TLP Motor also has a wide selection of cable lengths (up to 50 Meters) in both flexible and non-flexible options to meet your needs.

Interested in learning more about the new Kinetix 5100 or the TLP motor, or do you have other motion and drive application questions? Look no further than Revere’s Motion Solutions team. We can provide the right solution for any application. Revere specializes in Mechatronics – we can provide everything - Actuators, Gearboxes, Couplings, Motors and Cables. Contact your account manager or email us at customersupport@revereelectric.com to get started.

Blog written by Tom Roth, Revere Motion Product Manager

Stage 4: Installation and Validation Requirements

2020-09-25T19:54:40+00:00

The Functional Safety Lifecycle and YOU!

Stage 4: Installation and Validation Requirements

By Tyler Knutson, Automation Specialist, Safety

Machine safety has become more recognized than ever before. Employers and equipment manufacturers are tasked with providing equipment that is free from recognized hazards yet remain efficient, productive, & competitively priced. Revere Electric Supply, in partnership with Rockwell Automation, provides the tools needed to improve compliance, simplify development, reduce design time, and reduce costs.

In Stages 1 -3: You learned the importance of having a proven method of providing documentation showing a machine is safe to operate, mitigation techniques required, developing the functional safety requirements for your newly assessed machine, and using the tools needed to properly design & verify your safety system.

For Stage 4, we will focus on ensuring that your system was installed properly and to your specifications.

Some Questions to ask While Installing & Validating Your Safety System

Installation

Do the safety components meet the functional specifications?
Have the wiring methods been verified and proper grounding procedures met?
Has the correct signage and labeling been used?
Has wiring been installed per the electrical schematics?

Validation

Are the instructions on proper validation developed for each safety function?
Normal operation test: Safety input » Logic » Output
Abnormal operation test: Induce faults, short wires, break connections, remove wires, etc.

Have ISO 13849-2 Standards been followed during this process?

It’s important to make sure the system you’ve installed follows the documentation laid out in Stages 1-3. Validation of those systems ensures you or your customers that you are still current and meet the correct safety standards.

Note that Revere Electric is here to help you move forward with the validation process to meet the requirements set by your risk assessment and design process

What Items Should be Included in a Validation Checklist?

General Machine Information (Machine name/ Model, Serial, Customer Information, Tester Information, BOM)
Step by Step Verification Process

List out step number with description of verification action
Pass / fail
Indicate any changes / modifications made during the process

3. Focus on specific operations

Normal Operation: The Safety System responds properly to all normal Start, Stop, and Reset commands
Abnormal Operation: The Safety System responds properly to all forseeable faults with corresponding diagnostics
Safety input tests, safety output tests
Communication between relay tests, Configured settings tests

Rockwell Automation has assembled numerous Machinery Safety Functions that provide detailed validation documentation relating to your application.Along with a similar bill of material, you can mix / match different validation documentation to build a common process for your documentation.If you are working on current project, please use these as reference to help you move from your Risk Assessment (Stage 1) to Installation and Validation (Stage 4).

For more information into providing the appropriate products to meet your risk assessment and functional safety specifications, please review the following:

Rockwell Automation Machinery Safebook 5
Rockwell Automation Pre-Engineered Safety Functions

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IO-Link Hubs

2019-09-06T13:40:17+00:00

Why use an IO-Link Hub from Rockwell Automation

IO-Link Technology is a worldwide open-standard protocol that integrates sensors into Rockwell Automation’s Connected Enterprise by connecting the IO-Link enabled device into an IO-Link master module. You can deliver data from sensors directly into a control system in a very efficient manner. The flexibility of IO-Link capable sensors allows machines to operate more effectively by providing the controller with diagnostics.

IO-Link enabled sensors offer advanced features and diagnostics that can only be accessed through an IO-Link master module. These sensors act like standard sensors when not interfaced to an IO-Link enabled control system. This enables the stocking of the same sensors for standard I/O (SIO) applications and IO-Link applications, simplifying the selection process and reducing stocking costs.

https://ab.rockwellautomation.com/allenbradley/networks/io-link.page

When using IO-Link sensors, one gains the ability to configure, monitor, and troubleshoot smart sensors with Rockwell′s Studio 5000 programming software over Ethernet/IP. This functionality enables smarter machines by providing additional diagnostic information and more flexibility. Sensor configuration can be modified during product changeovers, and when a smart sensor is damaged, simply replace the sensor. The Logix control system will send the proper configuration to the new sensor. This eliminates the need for manual setup and making it easier to maintain machines. Utilizing IO-Link equates to more uptime and a more productive machine.

Sensors can be connected to an IO-Link system via an IO-Link Master (ArmorBlock® 1732E-8IOLM12R), as stated above, both standard sensors and IO-Link sensors can be connected. Multiple IO-Link Masters can be added as the I/O count increases.

But what if you are using more standard sensors than IO-Link capable sensors? When the I/O count increases, and you don′t need the extra sensor data and diagnostic information, the cost per point increases. And if several non-IO-Link sensors are connected to standard ArmorBlocks, even more cost is added.

What can be done to take advantage of what IO-Link technology has to offer, and at the same time reduce different technical solutions and costs?

The answer is IO-Link hubs from Rockwell Automation.

Rockwell Automation has three on-machine IO-Link hubs to give you the ability to connect more standard (non-IO-Link) I/O to your IO-Link system, without requiring separate ArmorBlocks. Now you can connect sixteen standard sensors to one IO-Link hub (does not provide IO-Link features) and uses only one IO-Link channel on the IO-Link master! If you need more than sixteen standard sensors, simply add another IO-Link hub to the next available IO-Link channel. The 1732E-8IOLM12R can connect to a maximum of eight separate hubs as needed!

There are three different ArmorBlock® IO-Link hubs to choose from:

1732IL-10X6M12 24V DC, 10 digital inputs and 6 digital outputs
1732IL-16CFGM12M12L 24V DC, 16 self-configurable inputs or outputs
1732IL-IB16M12 24V DC, 16 digital inputs

Refer to the Selection Guide, 732-SG001

Each ArmorBlock® IO-Link hub from Rockwell Automation is a fully sealed cast Nickel plated zinc die-cast package for demanding industrial environments. Each hub uses standard M12 connectors for easy cable selection.

Rockwell’s ArmorBlock® IO-Link hubs offer outstanding diagnostics including connection status, low sensor power, low actuator power, short circuits, invalid data, etc. And advantage over standard ArmorBlocks®. These diagnostics provide faster commissioning for the machine builder and quicker troubleshooting for the machine owner.

Lastly, ArmorBlock® IO-Link hubs are more cost effective than a standard ArmorBlocks® on Ethernet/IP. The price for a 16-point input hub is approximately $250 less than a comparable ArmorBlock® with 16 inputs. For machine applications requiring IO-Link and standard sensors, the IO-Link hubs from Rockwell provide outstanding value.

For more information, please contact your Revere Electric account manager or PAC/PLC Specialist.

IO-Link Hub Information: https://literature.rockwellautomation.com/idc/groups/literature/documents/pp/1732-pp001_-en-p.pdf

Additional Information

Find out how smart sensors with IO-Link can enable smart machines for The Connected Enterprise.

The benefits of IO-Link Technology include:

Reduced inventory and operating costs
Increased uptime/productivity
Simplified design, installation, setup and maintenance
Enhanced flexibility and scalability

Sensor Products

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Stage 4: Installation and Validation Requirements

2019-06-25T19:57:42+00:00

The Functional Safety Lifecycle and YOU!

Stage 4: Installation and Validation Requirements

By Tyler Knutson, Automation Specialist, Safety

For Stage 4, we will focus on ensuring that your system was installed properly and to your specifications.

Some Questions to ask While Installing & Validating Your Safety System

1. Installation

Do the safety components meet the functional specifications?

Have the wiring methods been verified and proper grounding procedures met?

Has the correct signage and labeling been used?

Has wiring been installed per the electrical schematics?

2. Validation

Are the instructions on proper validation developed for each safety function?

Normal operation test: Safety input » Logic » Output
Abnormal operation test: Induce faults, short wires, break connections, remove wires, etc.

3. Have ISO 13849-2 Standards been followed during this process?

Note that Revere Electric is here to help you move forward with the validation process to meet the requirements set by your risk assessment and design process

What Items Should be Included in a Validation Checklist?

General Machine Information (Machine name/ Model, Serial, Customer Information, Tester Information, BOM)
Step by Step Verification Process
- List out step number with description of verification action
- Pass / fail
- Indicate any changes / modifications made during the process
focus on specific operations
- Normal Operation: The Safety System responds properly to all normal Start, Stop, and Reset commands
- Abnormal Operation: The Safety System responds properly to all forseeable faults with corresponding diagnostics
  - Safety input tests, safety output tests
  - Communication between relay tests, Configured settings tests

Rockwell Automation has assembled numerous Machinery Safety Functions that provide detailed validation documentation relating to your application. Along with a similar bill of material, you can mix / match different validation documentation to build a common process for your documentation. If you are working on current project, please use these as reference to help you move from your Risk Assessment (Stage 1) to Installation and Validation (Stage 4).

For more information into providing the appropriate products to meet your risk assessment and functional safety specifications, please review the following:

Rockwell Automation Machinery Safebook 5

Rockwell Automation Pre-Engineered Safety Functions

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Modernization - The New Migration

2019-03-25T15:29:11+00:00

Minimizing the "Elephant in the Room"

Modernization, or as we use to say, migration (and I'am not talking about crossing the western frontier in a covered wagon; although that topic might come up a little later), used to be a straight forward concept because controls were simple. We would come across an obsolete piece of equipment and simply replace it with the updated version. Today, automation equipment is more complex, the luxury of just getting the updated version isn't available. Today there will be several pre-conditions that will need to be figured out and resolved prior to implementing a new control system. Here are some of the things to look for:

Network Compatibility
Software Changes
Application Code Conversion

I've found that all these issues can be overcome with a clear direction and a good plan. However, the most common objections to migration revolves around time and cost. How long will production be down? Where will the funding come from? What is the return on investment? For these reasons many automation migration projects are pushed out for future consideration. Obsolescence never seems to be a good enough reason to start the migration process. That's why it's important to understand the difference between migration and Modernization.

Modernization requires removing all legacy equipment and bringing the application to a modern state.The new technology is fully adaptable and equipped to meet future needs. The truth is, modernization provides:

Process improvements
Increased Production
Time Savings
Cost Savings

Additionally, Modernization will streamline the collection of machine data that allows you to conduct advanced business analytics. It's for these reasons we more accurately describe the transition of legacy controls to modern automation systems as Modernization.

Where should you begin when starting a Modernization project? On the surface the overall project looks like a huge undertaking. Especially when considering the pre-conditions I listed above. So here is where we circle back to the covered wagons. I read a book called "The Oregon Trail" and came across the phrase "seeing the elephant". It was a term the pioneers used when they were first heading out. I took this phrase as a modernization context; it's the enormity of how I will get from here (legacy equipment) to there (Modernization).

Modernization does not have to be done all at once. Like all tasks, it can be broken down into bite size pieces that can easily be put together to provide a complete modern system.

Revere Electric can lead you down the path of Modernization by conducting a walkthrough of your production line. Our trained specialists can identify risks within your control systems and suggest ways to improve your processes. Interested in learning more? Contact your account manager or contact as via email @ modernization@revereelectric.com.

And if you are not sure if you are ready to get us involved, below are some resources, tools, and websites that can jump start your modernization project... and hopefully, reduce the size of the elephant.

Rockwell Automation Literature Library:

This site is a consolidated depository of all of the Application Profiles, White Papers, Selection Guides, and Reference Manuals that are available to help with any modernization project. Just search "migrate" any key word like "SLC" then select a publication type "Application Profile" to locate the resource you need. Be sure to read the "Tips to improve your search results. Link to Literature Library

Rockwell Automation Modernization Website:

This site will provide the answers to Why Modernize?, Where to Begin? and how to develop a successful modernization plan. Link to Rockwell Automation's Modernization Website

Rockwell Automation Migration Tools:

Did you know that within all of the Rockwell Automation programming editors (Studio 5000, FTView ME Studio, RSLogix500, etc.) there is the capability to migrate legacy application code for use in new controllers and HMIs. Additionally, Rockwell's Product Selection and Configuration website will provide the selection tools required for your modernization project.Link to Rockwell Automation's Product Selection and Configuration website

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Troubleshooting and Maintenance: The Easy Way

2019-03-22T21:06:29+00:00

Making Troubleshooting and Maintenance Easy with FactoryTalk Analytics for Devices

Troubleshooting and Maintenance is a common challenge in every industry. Believe me, we understand it can be difficult to find the root cause of downtime.

Let’s take the following scenario:

There is a fault condition of a device on a machine? How does the operator/technician handle the fault? In most cases, they simply clear the fault and re-start the machine. Later in the day, another fault occurs, and he repeats the same steps he performed earlier. Eventually, a significant failure occurs, and the machine is down for hours or in some cases, a full day. Be aware the operator did not document the fault, either time it occurred, so nobody knew there could be a potential problem with the machine.

The traditional approach to troubleshooting this problem is to rely on intuition and experience. You must remember though, there is a mixed range of skill sets among the people on the plant floor. Sometimes they may be accurate, but often, they are not actually solving the problem. We have found that analytical decisions and actions are far superior to decisions based on intuition and experience.

What if device and system health could be provided to you automatically? Wouldn’t that make troubleshooting and maintaining your systems easier? Maybe it’s time to think about modernizing your approach? Rockwell Automation’s FactoryTalk Analytic for Devices is a new intuitive approach that provides device health and diagnostic data automatically for up to 2,000 devices. You can easily reduce downtime and mean time to repair with prebuilt dashboards notifying you when maintenance is required, or a device is about to fail.

Want to learn more? Check out the product profile and/or the video below. Your Revere Account Manager is always ready to help you with your troubleshooting and maintenance needs.

FactoryTalk Analytics for Devices Brochure

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Goodbye Legacy L4X Controllers…Hello Faster, More Flexible Ethernet Controllers

2019-02-28T18:24:11+00:00

Written by Greg Weichman, Revere Networking & Controls Product Manager

Believe it or not it has been 18 years since the launch of the CompactLogix; which brought the capabilities of the RSLogix 5000 software to a mid-range platform for the first time. Since it’s launch in 2001, many advances have taken place - two generations of hardware have come and gone, and it is now time to say farewell to the last available controllers of that era.

Rockwell Automation has recently announced the following discontinuations:

July 2020 - The 1768-L43 and 1768-L45 controllers
December 2020 - The 1769-L32E and 1769-L35E controllers

Once they have been discontinued, they will no longer be available for purchase. We know that many of our customers still rely on these controllers, but there are many reasons why moving into one of the new platforms is a blessing in disguise.

Increased Hardware Capacity

To start, none of these processors have the capability to go beyond version 20 of RSLogix 5000. This isn’t a planned obsolescence maneuver, but rather a matter of hardware capability. The newer generations of 1769 and 5069 controllers have more processing cores and more internal memory (separate from the programming storage) which is needed to enable new features; such as, project documentation storage (i.e. tag descriptions and rung comments), extended tag properties, program parameters, integrated motion support, integrated safety, and more.

Faster Scan Times

Another benefit is that scan times are much faster with modern controllers - with programs executing anywhere from two to twenty times faster. This new hardware is utilized to its fullest extent by programming it with the latest releases of Studio 5000. Version 20 of RSLogix 5000 is continuously being updated to remain current with Microsoft Windows, but it has not received any new features since its release in 2012, nor will it in the future.

Release of the 5069-Serial Module

In 2001, when the CompactLogix family first launched, Ethernet was not a prevailing technology in most industrial applications. Many applications required serial communications and the L32E and L35E have a serial port on the front making it a simple solution. Even though serial communications are becoming dated, the lack of a serial port on newer controllers prevented some people from being able to use them and take advantage of the newer technologies. Rockwell listened and we are happy to announce the release of the 5069-Serial module. This two-port device can be used as local or distributed I/O to support applications needing to talk ASCII, Modbus RTU, and Modbus ASCII. Mid 2019 the DF1 Serial protocol will be supported and more protocols will be added with future firmware releases. Sample programs can be downloaded from Rockwell’s Sample Code Library.

Two Ethernet Ports, Setup with the Same IP Address

Continuing with the Ethernet discussion, often a PAC needs to talk to two separate Ethernet networks. The most common example is when there is a need for a private network for IO and a public plant network for typical network devices. Previously, the easiest way for a Controls Engineer to achieve this was to use a 1768 controller, because the chassis could support two Ethernet cards and each one could be setup for a different network. For this reason, many people continued to use the 1768 controller, even though they were giving up all the useful features mentioned above. Now, we have multiple solutions for this situation. The 1769 platform has two Ethernet ports, but they are setup to have the same IP address, and therefore to be used in a linear or device level ring (DLR) topology on one network. To allow these controllers to talk to another network, we use a Network Address Translation (NAT) device such as the 1783-NATR, 9300-ENA, or select Stratix 5700 switches. The newest 5069 platform also has two Ethernet ports on each controller, but they are more configurable than the 1769. They can be setup to act in the same manner as the 1769 ports (for linear or DLR) or they can be configured to have two separate IP addresses, allowing the controller to natively talk to two separate networks the same way a 1768 rack with two Ethernet cards could. (Note, if you are using the 1768 platform for Sercos, the two directions forward are ControlLogix or migrating toEethernet based CIP motion devices.)

Simple Ethernet/IP Node Count

I am sure it will be of no surprise to any of you when I say that the number of smart devices being used in manufacturing increases every day.Our programmable controllers need to be able to communicate with every smart device, so the number of Ethernet connections available on newer controllers increases exponentially. With the older generation of controllers, calculations had to be done with devices on the network to determine TCP and CIP connections to make sure limits weren’t exceeded. Limits in an L32E processor were low with only 32 available of each, causing difficulty scaling with modern applications. Max Ethernet/IP connections would also decrease with increasing RPI creating even more confusion and frustration. Current 1769 and 5069 controllers have gone away from this confusing math by implementing a simple Ethernet/IP node count. All you must do is count the number of devices that will be in the I/O configuration of the project and then make sure to select a controller that will support the count (pro tip: plan some room for growth).

To recap, today’s systems are becoming more connected than ever before. Factory operators want to connect their equipment and contextualize data, so they can make educated business decisions in real time. Older control systems lack the processing and communication power to fit into today’s Connected Enterprise. Modern control systems provide ample connectivity, a new level of capability, greater ease of use, and more security. Luckily, converting applications among the families of CompactLogix is easily achievable with Studio 5000 software.

Revere’s team of automation specialists can help you modernize existing systems, bills of materials, and network architectures so you can take advantage of all the features we discussed today. Please reach out to your Revere Account Manager or Revere Specialist if you are interested in learning more or would like us to come out to evaluate an application.

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VFD Installation and Troubleshooting

2019-02-19T23:48:27+00:00

Recommended Installation Techniques and Troubleshooting VFD's

Ask yourself the following questions:

Are your variable frequency drives tripping frequently causing unnecessary downtime?
Are other devices in your panel tripping with no explanation?
Do your motors need to be replaced or repaired more often than you would expect?

If you answered yes to any of the questions above, then our recommendation would be to review the industry standards and recommendations for installing drives with really long motor leads. Following the installation techniques and recommendations will help any variable frequency drive application avoid those unneeded headaches and unnecessary downtime that costs precious time and money.

Rockwell Automation has both the industry standards and recommendations for drive installations available for all your VFD applications. Below are those documents and they are not only for the Powerflex Drives; but also include the industry standards for all VFD’s ranging from the incoming power filtering, to enclosure, enclosure layout, and all the way to the proper motor connection.

If you would like to learn more or have any questions, please do not hesitate to reach out to your Revere account manager or drives specialist for the expertise to help you properly design any of your new or existing VFD applications.

Documentation

Wiring and Grounding for Pulse Width Modulated (PWM) AC Drives

Industry Installation Guidelines for Pulse Width Modulated (PWM) AC Drives

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PowerFlex755T Drive Enhancements

2019-02-19T23:46:05+00:00

Rockwell Automation Expands TotalForce Capabilities andPower Range for PowerFlex 755T Drives

Aiming to offer the best-in-class power and process control solutions, Rockwell Automation has introduced the latest and upgraded suite of drive solutions - AllenBradley® PowerFlex® 755T drives. The new additions to the PowerFlex family help users reduce energy costs and increase machine uptime for assets running in high-demand applications. All compliant to the IEEE 519 specification, and built with the patented TotalFORCE™ technology, the expanded drive portfolio includes the PowerFlex 755TL low-harmonic drive, PowerFlex 755TR regenerative drive, and PowerFlex 755TM common DC bus drive system.

Learn more about TotalFORCE technology in this video:

Rockwell recently expanded the power ranges and capabilities of TotalFORCE technology for its Allen-Bradley PowerFlex 755T AC Drives from 10 to 6,000 HP. The expanded power range makes PowerFlex drives ideally suited for large power applications, such as pumps and fans requiring harmonic mitigation, and regenerative applications such as cranes, hoists, downhill conveyors, & dynes. This expansion brings harmonic mitigation, regeneration and common bus-system configurations to a wider range of high-demand applications.

The complete PF775T offering includes:

PowerFlex 755TL drive: the PF755TL uses active front-end technology and an internal harmonic filter to reduce harmonic distortion. It is now available from 10 to 1,800 HP (7.5 to 1,400 kW)

PowerFlex 755TR drive: the PF755TR uses active front-end technology and includes both regenerative & harmonic mitigation solutions. The drive helps reduce energy consumption and costs by delivering energy back to the incoming supply, resulting in a more energy-efficient solution. It is now available from 10 to 6,000 HP (7.5 to 4,500 kW).

PowerFlex 755TM drive system: the PF755TM uses active front-end technology to allow the user to build the system that best fits their needs for regeneration and coordination of multiple motors in common bus configurations. To optimize system requirements and meet power-consumption needs, you can select from a series of predesigned modules with a power range from 250 to 6,000 HP for motor side inverters and a range of 70 to 4,800 kW for regenerative bus supplies.

The new power range, enhancements to the patented TotalFORCE technology & other new capabilities include:

10 to 6,000 HP (7.5 to 4,500 kW)
More powerful adaptive control capabilities that will allow the drive to monitor machine characteristics that can change over time and automatically compensate for the changes that occur.
New Adaptive tuning feature to block resonance and vibration
New Predictive maintenance features that will provide real-time information about the health of the PF755T
Integrated Safety functions option module on EtherNet/IP offers advanced safety features
Anti-Sway feature helps lifting applications (cranes & hoists) achieve greater stability
Permanent magnet motor control for increased energy savings

Combined, these new TotalForce technology capabilities help reduce time to commission, optimize performance and enable simplified maintenance & serviceability throughout the full lifecycle of PowerFlex 755T drives for a broad range of applications.

Please click on the links below to learn more about the PF755T drives and new enhancements or contact your local Revere drives specialist to discuss your application.

https://ab.rockwellautomation.com/Drives/Low-Voltage-AC-Drives/PowerFlex-755T-Overview

https://ab.rockwellautomation.com/Drives/PowerFlex-755T-Overview

https://ab.rockwellautomation.com/Drives/PowerFlex-755T-Overview#whatsnew

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Rockwell Automation's New PanelView 5000 Will Not Disappoint

2019-01-16T16:20:31+00:00

Rockwell Automation's PanelView 5000 HMI Will Not Disappoint

by Robert Janociak, PLC/HMI Product Manager

Every customer has a unique perspective on the PanelView5000 family. Some think it’s old news. Others are not familiar with it at all. Rockwell Automation continually offers new products with new features and benefits – but the tech savvy person (me included) is always wary of the latest and greatest product offering. Does it do everything it is supposed to? Are there any bugs or as I like to call them “Undocumented Software Features”? These things are inevitable with new products, but I have decided that now is the time to seriously start thinking about the PanelView 5000 and here’s why.

First, let me share some history. If you attended the 2015 Automation Fair in Chicago there was a sneak preview of the PanelView 5000 prominently on display. It was exciting to think that
Rockwell was going to offer the next generation of PanelView’s to replace the PanelView Plus Family. After the show, Rockwell Automation quietly took the product away, redesigned it, and recently relaunched it. Of course, when a manufacture first releases a product, it doesn’t have all the bells and whistles that you would expect. It was a work in progress. Most people steered clear of the new HMI’s and were waiting until more features were released.

So fast forward to today. Rockwell currently offers two models; the 5310 and the 5510. As with past PanelViews, there is a “Lite”version that typically has less hardware/software capabilities, but is an optimal, affordable option for many applications. Then there is a “Full” feature version for more demanding applications. However,the biggest change in the new PanelView 5000 line is the operating system. No more Windows CE!!! The new platform runs a proprietary Linux Operating System that ensures a long product life.

Today’s PanelView 5000 uses a new software called ViewDesigner and it’s included with Studio 5000 V27 and above. View Designer is very intuitive. Simply put, it takes a fraction of the time and less clicks to make a basic screen when compared to Factory Talk View ME. Scalable vectorgraphics with built-in animation make for visually appealing displays. There are also features like pre-made system error pop-ups that give you greater troubleshooting capability and a home button that pops-up all your navigation buttons to save screen real-estate.

The key benefit of having View Designer included with LogixDesigner is that you can automatically share tags between the two.This includes access to Logix Designer’s new extended tag properties which include Min/Max Values and Logix-Based Alarms.

Logix-Based Alarms are unique because you create the alarm in Logix under the extended tag properties; including how it’s triggered and how the message needs to be displayed. No longer do you have to regenerate the entire alarm tag list in your HMI software. This saves not only time in developing, but also eliminates the excess polling communication that happens in the background. Now, the controller will just push the alarm to the HMI with the exact time and date stamp as it occurred.
One question that we get asked all the time is, “Is there a conversion utility from my existing Factory Talk View ME software to View Designer?” The answer is not at this moment. There are just too many unique things that View Designer does differently that would make a conversion utility challenging to produce.

I know that not everyone is ready to make the switch to the new PanelView 5000, and if you are one of them, don’t worry. The PanelView Plus family along with Factory Talk View ME are not being discontinued and will continue to be supported and enhanced. However, if you are working on a new application, I would seriously consider the PanelView 5000. By the way, If you have Studio 5000 installed, go ahead and give View Designer a try. You will not be disappointed.

Rockwell Automation PanelView 5000 Webpage

Studio 5000 View Designer Webpage

Helpful View Designer Videos

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Efficient Repair Process Though CHAMP

2018-12-04T20:17:07+00:00

Revere "CHAMP"; Making Your Repair Process More Efficient

Excess spares and inefficient processes make it difficult to establish a proper parts repair pool to keep your production environment functional with minimal downtime. Revere has a new resource called “CHAMP” that can help you manage your repair process through the Rockwell Automation remanufacturing methodology.

Think of Revere’s CHAMP as your local resource to help simplify the remanufacturing transactions surrounding your inventory and act as a single point of contact for everything needing repairs, warranty, or even replacement. Revere’s CHAMP could be an integral resource as an extension of your maintenance department. The CHAMP will make regular visits and be readily available to help expedite the repair process, maximize your uptime, and escalate any repeat product family repairs.

Keep in mind that Rockwell also repairs over 200,000 non-Rockwell Automation products from 7,000+ manufacturers.

Contact a CHAMP today for your initial consultation.

Wisconsin (CKohn@revereelectric.com) - Illinois (ssantamaria@revereelectric.com)

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Allen Bradley 100-D Contactors Reach End of Life

2018-10-22T21:15:00+00:00

New 100-E Large Frame Contactors Replace the 100-D Series as of March 31, 2019 - Creating Efficiencies and Cost Savings

Allen Bradley’s popular 100-D line of contactors is nearing end of life status. Beginning on March 31, 2019, the 100-D will no longer be available. The replacement 100-E contactors provide a narrower panel footprint, reduced weight, lower coil power consumption and simplified selection.

The 100-E , ranging from 116 to 2650 amps, offers a wider range of sizes to choose from than the 100-D and many other benefits. The 100-E offers AC/DC control voltages with their standard electronic coil. The new coils reduce the inrush requirements by half or more, allowing you to save money on your power supply or transformer. Additionally, the physical size reduction of the frames and quick connect bussing solutions for connecting to circuit breakers reduce panel space requirements and make installation easier as well.

For more information, check out the documentation below or contact your Revere Account Manager for more information.

Bulletin 100 Contactors

100-D to 100-E Migration Path Bulletin

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Rockwell’s New Flex 5000 Distributed I/O

2018-07-25T16:38:25+00:00

Rockwell Automation’s highly successful 1794 Flex I/O just got an upgrade. The new 5094 Flex 5000 I/O product line is finally here. It has a whole host of features that can handle just about any demanding application. The positioning of this In-Cabinet I/O offering is geared more towards the process environment where uptime is critical. However, this is not to say that any application benefit. Whether your looking for higher performance (1ms Screw to Screw response time) or flexible network architecture, the New Flex 5000 delivers.

With any new product, the Flex 5000 will get released in stages. First the Standard I/O modules, then Safety and High Density 32 Point I/O modules following shortly thereafter. Aside from all the other features listed below, another benefit is having additional remote I/O safety options to choose from, and High Density I/O modules are key when selecting this I/O family above the 1734 Point I/O offering.

Now it’s important to note that you’ll need Studio 5000 Version 31 or greater to be able to use the new I/O platform. Also because of its high speed and all its features, only the ControlLogix/GuardLogix 5580 or CompactLogix/Compact GuardLogix 5380 generation of programable automation controllers will be able to be used. The Stratix 5400 all-Gig switch is a nice compliment to the architecture.

Here’s what you can expect to get with the New Flex 500 I/O family:

It’s Fast

1 GB backplane
Up to 200 μs RPI support

It’s Intelligent

Secure embedded Web Server
Input Power & Temperature Diagnostics
Dual Color LED for Status and Diagnostics per I/O point.
Capable of RIUP (Remove & Insertion Under Power)
Add and configure modules online
CIP Sync and PTP (Precision Time Protocol) support

It’s Secure

Module Birth Certificates (QR Codes on the front give hardware information)
Digitally Signed Firmware support

It’s Network Ready

Dual 1GB Ethernet Connections
Supports Linear, Star, Device Level Ring and Parallel Redundancy Protocol (PRP) topologies
Optional Fiber Connections w/ SFP adapters

It’s Designed for Rugged Environments

Temperature Ranges -40 °F...158 °F (-40 °C…70 °C)
Certified for Class I, Div. 2 Zone 2 Groups A, B, C, D
Class G1, G2 and G3 (XT version adds conformal coating to meet Class G3)

Interested in learning more, contact us at any time.

Download Flex5000 Product Profile

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Migration is Inevitable. Here's How We Would Do It.

2018-06-05T14:21:34+00:00

It’s hard to believe that remote I/O has been around for over thirty years. While its served you well, you’re finding out that it is unable to perform to today’s control requirements and standards. Sooner or later you’re going to have to upgrade your legacy DH+ & Remote I/O systems.

I think it’s safe to say that Drives and PanelViews are the pulse of your plant. Drives help ensure that processes; such as bottling, filling, cartoning, and palletizing, are running efficiently and smoothly. PanelViews give you the critical insight into your control system. Should either one of these fail, your entire control system could be affected. Replacements for legacy Remote I/O drives and PanelViews are in short supply, and are quickly becoming unavailable. What should you do?

Today’s modern control systems run on EtherNet/IP networks. It just so happens that ProSoft Technology has developed an innovative modernization gateway that will allow you to convert Remote I/O and DH+ to EtherNet/IP. Now you can upgrade your legacy Remote I/O control system in phases; eliminating the need for extended scheduled downtime that would be required to upgrade your system.

The gateway we are referring to is ProSoft’s AN-X2-AB-DHRIO. The gateway enables the ControlLogix or CompactLogix systems to control PLC, SLC, or Flex I/O racks over Remote I/O. The module can be added to an existing network and monitor the changing states of I/O without interrupting the process. This provides you with the ability to build and verify the new control system before switching over, minimizing risk. The gateway also has a built-in MicroSD card which stores configuration files and firmware. This Micro SD card can be transferred to another gateway to resume operation in the event of a disaster.

The AN-X2-AB-DHRIO has multiple operating modes including:

HMI - Upgrade up to 8 Remote I/O PanelViews to EtherNet/IP enabled PanelView Plus 6/7 terminals without modifying PLC code
DRV - Upgrade up to 4 legacy drives on Remote I/O to EtherNet/IP Drives without modifying the PLC code
SCAN - Control racks of Remote I/O from and ControlLogix or CompactLogix processor
DHP - Remote monitoring, upload, download over EtherNet/IP to a DH+ network
ADAPT – Monitor the Remote I/O network

Interested in learning more, contact us at any time.

Download ProSoft’s AN-X2-AB-DHRIO Product Profile

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What I Got Out of Attending RAOTM

2018-05-29T16:05:09+00:00

Why Attend Rockwell Automation on the Move?

Wow! I had such a great time at the Rockwell Automation On The Move in Milwaukee! The region had record attendance; 757 customers over two days! What an amazing opportunity! Here’s what I got out of it:

·         I saw new products from Rockwell Automation and the 65 Encompass Partner manufacturers.

·         I was able to collaborate with colleagues and customers – at the same time!

·         I gained technical insight by discussing solution scenarios for challenging applications.

·         I was able to Network, Network, Network!

So, what was my favorite part? You guessed it, networking with you! It’s not often that you get the opportunity to discuss projects with everything you need right in front of you. I could walk customers over to a live demo or I could bring in a Rockwell-Automation and/or an Encompass Partner expert to join the discussion. We traded contact information and now we have even more resources at our disposal for future applications. Networking also allowed us to answer many of your questions right on the spot; and for those requiring further discussion, we documented those questions to be answered later.

The Wisconsin Center proved to be a great venue, providing for an ample exhibit floor and plenty of room for the 45 Tech Sessions and 16 Hands On Labs. The Tech Sessions had very good attendance, with topics pertaining to the timely issues of the day. The Hands On Labs proved to be very popular, with a waiting list for many of the sessions. Rockwell even had to add extra lab sessions to help with the increase in demand.

I look forward to working with all of you as we follow up with existing projects or explore new opportunities. Attending Rockwell Automation On The Move was well worth my time and effort and I hope that attending Customers and Encompass Partners felt the same.

I can’t wait until we host Rockwell Automation’s Automation Fair in November of 2019 in Chicago. Automation Fair provides even more opportunity to learn, explore, and collaborate. And next year is Revere’s 100-Year anniversary and we are planning to celebrate in style. We look forward to you celebrating with us!

Sincerely,

Jim Armstrong, Wisconsin Automation Manager

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Soft Starters: To Bypass or Not to Bypass? That is the Question

2017-10-06T15:18:32+00:00

Soft starters are designed to limit current or soft start (ramp up the voltage) of a motor. The same holds true for braking or soft stopping. Simple settings perform the start and stop well. So what about in-between the start and the stop? Do you continue to use silicon-controlled rectifier (SCR) control or do you utilize a bypass contactor?

Some soft starters are fully solid-state - meaning no bypass is needed - and are IEC rated AC-53a for running on SCR control continuously on a squirrel-cage motor. Other soft starters are hybrids, which means that they are rated AC-53b intermittent duty and use a bypass when the motor is up to speed.

Here are some fully solid-state soft starter advantages:

Can be used in a continuous run mode
No mechanical wear and tear of components
Excellent in high vibration applications
Ability to handle non-traditional motor loads such as resistive and transformer loads
Higher operations per hour compared to hybrid soft starters with integrated bypass, limiting factor being the bypass contactor itself

Applications that are well suited for a solid-state soft starter are:

Rock crushers: the environment is dusty, dirty and has a lot vibration if the soft start is mounted close to the crusher
De-barkers: similar to the rock crusher for the environment
Hammer mills: places with a lot of vibration - where an electro-mechanical would have issues
A solid state soft starter can handle the same applications as a hybrid soft starter

Did you notice a common theme? All of the applications involve harsh environments. Dirt and dust will not affect functionality because there are no mechanical parts to let dirt in and shorten the life of the unit. Some soft starters take this a step further and provide conformal coating, adding an extra level of protection against conductive dust or environmental corrosion.

The hybrid soft starters typically contain SCRs not rated for continuous duty because this controller is designed to utilize SCRs to start and stop, and no more. Use of a bypass contactor, either internal or external, allows an application to run continuously after the starting algorithm stops and the motor is at-speed. The bypass will open once a stop or fault command has been provided.

Here are some advantages of an internal bypass:

Smaller form factor
Less heat dissipation
Simplified wiring

Here are some advantages of an external bypass:

Fully rated contactor
Less diagnostics preventing non-critical nuisance trips
An application with frequent high current surges

The best applications for hybrid soft starters include:

Fans
Pumping
Conveyors
Less harsh environments

You need to know the motor application that will be controlled by the soft starter. After the start and stop method is selected, think about how the run mode in between is to operate. Then pick the appropriate run mode to fit the application. To assist with the thought process, ask the following about the application:

Clean environment
Vibration
Space an issue
Desire full diagnostics at full speed
High duty cycle

Interested in learning more, contact us at any time.

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Leading Edge Soft Start Control – The SMC-50: Excellent for Mining Applications

2017-10-06T14:51:45+00:00

The Allen Bradley SMC-50 range of soft starters are a premium offering within Allen-Bradley’s portfolio. The SMC-50 is available from 90A - 520A and is suited to mining and industry applications.

Featuring the new sensorless linear acceleration and deceleration starting and stopping modes; exacting motor control is achieved even under varying load conditions. In addition, an extensive range of start and stop modes are included as standard, including pump, braking and torque control modes - ensuring application functionalities are fully satisfied.

Advanced motor protection functions, power monitoring and metering, the SMC-50 also includes full fault diagnostics with a real time clock. Furthermore, emergency run mode, motor winding heater and slow speed functions offer application flexibility. Utilizing solid state three phase power structure, the SMC-50 offers flexibility of installing an optional external bypass contactor for minimal heat dissipation during run time.

What makes the SMC-50 ideal for mining is the conformal coating. Dirt and dust will not affect functionality because there are no mechanical parts to let dirt in and shorten the life of the unit. The SMC-50 takes this a step further and provide conformal coating, adding an extra level of protection against conductive dust or environmental corrosion.

The SMC-50 offers easy setup and integration onto multiple network platforms including dual-port or single-port EtherNet/IP, DeviceNet, ControlNet, Modbus, Profibus and more. In addition, a full complement of field fit expansion cards are available, catering for additional I/O as well as ground fault and PTC inputs.

Available in open frame, enclosed & modified to suit your needs, the SMC-50 makes it easier to access essential plant and production data, and reduce your operating costs. Make the Allen-Bradley SMC-50 range of soft starters your first choice.

Coming soon, SMC-50 with internal bypass late 2018.

SMC 50 Solid State Smart Motor Controller Brochure.pdf

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Sytech XLReporter – An Entryway into Collecting Data

2017-07-20T16:34:50+00:00

When it comes to collecting and reporting data there are many different types of solutions available. Different types of data, collection requirements, and reporting standards determine the selection of tools available to accomplish the job. One of the more flexible and powerful solutions we have seen for small to medium systems is a product made by Sytech Inc. called XLReporter.

XLReporter is the first reporting software for Industry to produce Workbook, PDF and Web reports from templates designed in Microsoft Excel. This means there is an extremely low learning curve to begin collecting data and generating reports. Let’s go over some of the creative use cases.

Example 1) Live Data Collection to Reports

We used FactoryTalk Gateway or RSLinx Classic to provide data to the XLReporter software. At a set interval or based on an event driven by the PLC, XLReporter will take live data and store it into an Excel Workbook that can be customized based on your needs.

We choose to have a line graph with the table of values below it. To organize our data, we can create a new workbook for each day and a new sheet within each workbook for every shift. At the same time the workbook is updated, we update a web report allowing semi real-time viewing of the report by any user on the network. And finally, at the end of each shift, we create a secure PDF report of the entire day to make sure we have a permanent record.

Example 2) Panelview Plus – Data Store Plus ActiveX

We have a Panelview Plus recording data using the Data Store Plus ActiveX. The output of this collector is .csv files with a new one started each day. We set XLReporter to automatically grab each CSV file from the Panelview as it is completed and have it store the file in the project directory. Now all the CSV files are treated as a single source of data.

Why is this cool? Without it, to look at data over several days, we would have to open several CSV files and copy and paste a lot of data. Now we can open pre-created reports and enter parameters to generate an on-demand report that is continuous between our entered start and stop dates/times. We can then go full circle and display these reports back on the Panelview!

FactoryTalk View SE – Data Logs and Alarm and Events

FactoryTalk View SE has the native capability to store both data and alarm information in a SQL database. XLReporter can act as the ‘front end’ to this database and create reports based on a time interval, an event, or on demand. The data in the SQL database can quickly become useful information in the form of a spreadsheet, PDF, or web report. For on the fly trouble shooting, we can create reports on demand over the desired time frame with the desired information. Use the Alarm and Events data to produce specific alarm dashboards by setting filter and search criteria. Add historical data to the dashboard and learn if there are correlations between process deviations and alarm behavior. If you have a FactoryTalk Historian SE, that data can be tied in too!

You can read more about these and other use cases from the excellent ‘Report from Rockwell Automation’ page on Sytech’s website (http://www.sytech.com/solution-report-from-rockwell-automation.asp). Make sure to check out the video library while you are there.

If you have any questions, want to see the software in action, or want to discuss an application where you think Sytech’s XLReporter could be a good fit, contact us at any time.

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Stratix 2500 Lightly Managed Switch

2017-07-20T16:30:11+00:00

We are so excited about the Stratix 2500 Lightly Managed Switch. Essentially, this switch closes the gap between unmanaged and managed switches. It offers a simple installation, much like that of the unmanaged switch, at a relatively low cost, while still meeting today’s industrial network demands.

The Stratix 2500 enables network connectivity in applications where traditional unmanaged switches lack the ability to provide network resiliency, diagnostics, and security; allowing you to achieve higher productivity and network reliability.

The Stratix 2500 offers consistent prioritization and delivery of traffic on a per-port basis and helps ensure that critical traffic is transported end to end with priority.

Features and Benefits

Premier Integration into the Integrated Architecture® System

Add-on Profile for configuration via Studio 5000 Logix Designer® design environment and FactoryTalk® View Faceplate for diagnostics

Reduced Total Cost of Ownership:

VLANs allow for logical segmentation in a single switch, which reduces total number of switches needed

Improve network resiliency:

STP helps detect network loops and prevents them before the network stops
IGMP enables multicast for data traffic control

Increase network security

Port security allows users to disable ports, or control end device connectivity based on MAC address
SSH and HTTPS provide secure connectivity

Minimized downtime

SNMPv3 and Syslog monitor network-attached devices to uncover errors and decrease downtime
Diagnostic information and alarm relay provide actionable information to resolve issues faster
Port Mirroring to aid network troubleshooting without affecting the running state of the network

Learn More About Stratix Switches

Stratix 2500 Switch Brochure

Stratix Switches - Rockwell Automation Web Page

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Logix - The Latest and Greatest!

2017-03-17T19:46:15+00:00

Does Your Application Require a Wicked Fast Controller With Two Independent Ethernet Ports?

If you answered Yes, the CompactLogix 5380 is what you need. The CompactLogix 5380 is the newest release of a midrange scalable high performance automation controller within the CompactLogix family of PACs. The 5380 controller will enable faster performance, increased memory capacity, and additional security to meet the growing demands of Smart Machine technology.

CompactLogix™ 5380 Features and Benefits

Provides up to 20% more capacity – 5, 8 and 10 MB
5 – 20x performance increase.
Dual Gb Ethernet ports, configurable for dual IP or DLR
Energy Storage module eliminates the need for a battery
Digitally-signed controller firmware adds additional layer of security
< 500 μs screw to screw times with 5069 Compact I/O
Display provides enhanced diagnostics
Up to 80 EtherNet/IP nodes
Up to 32 axes of motion on EtherNet/IP

Learn more

Maybe an Integrated Safety Controller with a SIL 3 PLe Rating is What You Need?

The Compact GuardLogix 5370 is the newest release of a midrange integrated safety controller. This scalable control platform provides machine builders with a controller that meets the need for a high performance automation controller and incorporates SIL3, PLe, CAT4 safety requirements. Built on standard EtherNet/IP this controller provides a simplified architecture to meet the safety demands for today’s machine builders.

5370 Compact GuardLogix® Features and Benefits

Integrated Safety on EtherNet/IP
Supports 1734 Point Guard and 1732 ArmorBlock Guard I/O
Single controller, single software, single network for standard, motion and safety control
Up to SIL 3, PLe safety functions
High Integrity Add-On Instructions
Removable 1-Gb Secure Digital (SD) card improves data integrity.
Integrated motion on EtherNet/IP up to 16 axes.
Integrated Safe Torque Off (SIL3, PLe) with Kinetix 5500

Need More Memory to Run Your Beefed Up Applications? The New 1769-L19ER-BB1B Has up to 1Mb of User Memory Available.

The CompactLogix 5370 has a new product line extension within its popular midrange automation controllers. Specifically, the 1769-L19ER-BB1B. It increases the available user memory in the L1 family of controllers to 1MB. The 5370 L1 controllers have long been favored by machine builders looking for a high performance controller with embedded I/O.

5370 CompactLogix™ L1 Controller Addition Features and Benefits - 1769-L19ER-BB1B

1MB user memory
Embedded digital I/O (16 DC inputs, 16 DC outputs)
Expandable Local I/O using up to eight 1734 Point I/O modules
Supports up to eight EtherNet/IP nodes
A built-in 24VDC nonisolated power supply
Dual EtherNet/IP ports for linear and ring topologies.
USB port for firmware download and programming.

Learn More

This is the BOM if Your Bill of Material Requires High Speed I/O Performance, Extended Memory Capacity, and Vast Amounts of Motion Axes.

The ControlLogix 5580 is the newest advancement within the ControlLogix family of controllers. The new ControlLogix 5580 controller provides up to 45 percent more application capacity and includes an embedded 1-gigabit Ethernet port to support high-performance communications, I/O and applications with up to 256 axes of motion.

5580 ControlLogix™ Features and Benefits

Provides up to 45% more capacity
1 gigabit (Gb) embedded Ethernet port enebles high-speed I/O and motion control.
Controller functions optimized for maximum system performance.
Energy storage module removes the need for batteries.
5-20x performance increase
< 500 μs screw to screw times.
Up to 300 EtherNet/IP nodes
Up to 256 axes of motion

Learn More

Do you Require the Enhanced Productivity Features That Are Found in Studio 5000 Logix Designer and Redundancy in Your application?

Studio 5000 Logix Designers newest firmware version supporting redundancy as just become available. This latest revision supports all the 5570 (L7) processor family.

ControlLogix® Redundancy V24.052 Benefits

V24 Logix Designer in ControlLogix® Redundancy Implementations
Available for download at Rockwell’s Compatibility and Download Center

Download Now

Need a Smidge More Room in Your Control Cabinet? The New Slim Power Supplies May do the Trick.

The Bulletin 1756 Slim Power Supplies offer a 29% reduction in width for ControlLogix control systems when space is limited.

1756 Slim Power Supply Features and Benefits

Supports all 1756 series B and C standard chassis.
Supports series B and C of the 1756 Extended Temperature XT Chassis.
Offers the same mounting clearances as existing power supplies.
Meets a wide range of voltage requirements with both standard and XT versions.

For Your Redundant Power Supply Applications, We Have New Right Angle Cables to Help Save Space.

The Bulletin 1756 Right Angle Redundant Power Supplies Cables reduce the minimum installation required for redundant power supplies.

1756 Right Angle Redundant Power Supply Cables Features and Benefits

Supports all series of standard redundant power supplies.
Compatible with XT cable adaptors and power supplies.
RoHS compliant
Same list price as standard cables.

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Predictive Maintenance with the PowerFlex 750

2017-03-16T15:11:39+00:00

Lost productivity caused by poor performance or unplanned failure of your automation assets can significantly reduce your revenue and profitability. It is important that you provide plant-wide maintenance services on all your automation assets. The question remains, what is better predictive or preventative maintenance?

What is the Advantage of PREDICTIVE Over Preventive Maintenance?

In order to properly maintain your assets, you need to keep track of various parts of your system. Things such as:

How long has the fan in my drive been running?
When is the next time my machine needs to be lubricated?
How many cycles are on that relay contact?
What is the runtime on my motor’s bearings?

With the PowerFlex 750 predictive maintenance you can monitor certain parameters within the drive, which reduces the high cost of unplanned downtime due to some of these common factors:

Lost revenue due to extended downtime
Long delivery time due to unscheduled replacement parts
Lost material – work in process
Lost productivity of workforce
Not having the correct resources – people and parts

Why Does Predictive Maintenance do a Better Job Than Preventive Maintenance?

We feel that Predictive Maintenance optimizes your maintenance overhead in people, spares, and the time that you actually require. If you do maintenance too often, then you waste time, manpower, and money. If you do maintenance too late, you may cause downtime and increase your costs.

Predictive’s scheduled maintenance plan is a best guess for when maintenance might be required. Because it is difficult to keep track of all the changes in a plant, the result of Preventive Maintenance’s schedule is inevitably wasted money.

Example:

Larger products = heavy loads, but fewer and longer cycles
Large orders = running 2 shifts
Personnel changes can lead to missed scheduled maintenance all together.

The Predictive Algorithm in the PF750 takes into account ambient temperature, air quality, humidity, Vibration, runtime and cycle counts. These are used to adjust the timing of when maintenance is really required, and not just on all the moving parts of the drive itself, but your motor and machine bearings.

Predictive maintenance parameters can be monitored in a controller. This can be very useful when monitoring many drives in a system. The controller can either read the parameters in the drive through Datalinks, or through message instructions in the controller code. The controller can then be used for system maintenance analytics and sending predicative maintenance data throughout the plant.

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For more information on the PowerFlex 750 and Predictive Maintenance, contact your Account Manager or contact us on our on-line Solutions Inquiry Form.

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Why Use the Rockwell Kinetix 5X00 Series Drives

2017-03-15T19:39:33+00:00

Every Engineer is looking for ways to get things done more efficiently. Machine startup and commissioning is frequently a time consuming part of the build process. One way for Engineers to improve on their startup times is to choose Rockwell Automation for their controllers, drives and motors.

The Rockwell Kinetix 5X00 series drives have advantages that become apparent in many stages of the design/build process. Here are some differentiators:

1. During the initial design stages, a wider range of inertia values is acceptable.
2. During commissioning, the drive setup and tuning is quicker than ever before.
3. During normal machine operation, the advanced tuning features can compensate for mechanical wear.
4. If a product changeover is required, the drives can easily adapt to the new loads.
5. A drive system that’s tuned well can reduce mechanical resonance and wear.

Additional features of the 5X00 Series Drives - Load Observer

Rockwell Automation’s 5X00 series drives includes a feature called the Load Observer. The Load Observer eliminates the need to auto-tune by automatically compensating for small and large loads that can vary over time. The use of Load Observer will provide higher performance than traditional auto-tune methods, and do so using less Engineering hours.

Load Observer works by estimating the load attached to the motor and adjusting that value at the drive update rate. The feedback system then uses this calculated value to allow the motor to perform as though it was unloaded. The result is higher machine performance under varying loads and changing conditions, with more tolerance for backlash and compliance in the servo system.

Additional Features of the 5X00 Series Drives - Tracking Notch Filter

Another feature included with the 5X00 series is a Tracking Notch filter. The drive identifies the primary high frequency resonance and sets a notch filter to counteract this resonance. The drive will continue to track the system response and modify the notch filter as necessary. In addition, the drive is able to monitor this resonance and make the control aware if the resonant frequency moves outside predefined limits.

Resources

Rockwell Motion System Tuning

Rockwell Drives and Motion Accelerator Toolkit

Rockwell K5500 Installation Instructions

Rockwell K5500 Manual

Rockwell K5700 Manual

For more information, please contact your Account Manager or fill out our on-line Solutions Inquiry form

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