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© 2015 AWC, INC NextGEN Control System Workbook
AWC
NextGEN CONTROL
SYSTEM WORKBOOK
GOING DIGITAL GOING GLOBAL
GLOBAL NEEDS
High Accuracy & Performance Advanced Functionality Remote Control Diagnostics/Reduced MaintenanceModification Ease Competitive Price
CHALLENGES
Development Time and Resources Rapidly Advancing Technology Need to Integrate into Plant Wide Systems Global Requirements and Certifications
NextGEN WORKBOOK
NextGEN Six Step ProcessApplication Needs Assessment Reducing Variability Control Panel Best PracticesProduct Life Cycle Support & Services
Our team of over 400 engineers, technical
support and service specialists working across
30 customer care centers are ready to help you
win with the best possible solutions for safe and
efficient operations.
NOTE: The guidance provided within the workbook is intended to augment not replace standard engineering practices.
….. 2….. 3….. 6….. 7….. 8
ONE WORLD
ONE CONTROL SYSTEM
© 2015 AWC, INC NextGEN Control System Workbook
NextGEN SIX STEP PROCESS
NextGEN Automation, Drives, Control Systems
1. ANALYZE APPLICATION NEEDS
1. What are the requirements for the initial system?2. What are the typical project variables? What makes each project unique?
i.e. type and size of processing equipment; pumps, separators, etc.3. What is the typical number of pieces of process equipment and range of sizes in Small, Medium and Large Projects?
i.e. Small projects have 1 and 2 pumps under 20 HP, Med projects have 3-5 pumps between 20 and 100 HP, ..4. What features are typical project “add ons”? (Power load monitor, remote telemetry, etc.)5. What new capabilities or features are customers asking for?
Analyze application needs and variability
2. ANALYZE EXISTING DESIGNS
6. Request typical designs (drawing package) – Offer NDA for proprietary information7. Receive list of product to cross over - Include anticipated yearly usage and customer part numbers8. Load BOM into Excel - Break down parts by product hierarchy - EX: Controls –> Pilot devices -> Pushbuttons9. Identify key attributes for product selection - EX: Voltage, Ratings & Certifications10. Visit legacy brand websites to download all pertinent data (data sheets, drawings, certs)11. Fill in attributes and add any fields needed in Excel, noting any discrepancies or questions12. Identify the best fit alternative suppliers to the parts on the existing BOM13. Use the Design Guide to identify the best cross overs based upon the competitors’ specifications - Use Design
Guide parts to provide the ultimate Design Assurance! 14. For any parts which do not cross to Design Assurance parts, use our technology partner BOM conversion tools
(website, spreadsheets, …) to identify close matches15. Using attributes, datasheets and vendor BOM conversion tools; identify best product to convert to16. Where possible and commercially viable, reduce unnecessary variability17. Have another technical resource review selection/conversion choices18. Use Design Guide Format when possible to compare the legacy and AWC products selected19. Build a data sheet book by BOM Item Number with the legacy and AWC Data Sheet, highlight critical sizing and
selection data on each20. Price the AWC Products - Use/Load the Tier or Custom CPA21. Work with our vendors to get rebates so that we can offer competitive pricing 22. Meet with customer to review the compare XLS cross over, explain the process taken, decisions made and
discuss any questions - Include links to on-line data sheets or bring data sheet book
Design & BOM analysis feature vs price comparison
3. DESIGN
23. Confirm customer agreement both on component pricing and brands/models before continuing24. Design panel layout and update drawings25. Get customer approval before moving to next step
Panel design and drawing conversions
4. PROGRAM
26. Confirm customer agreement on programming and configuration guidelines before continuing27. Program PLC logic along with HMI configuration and test functionality28. Get customer approval on program and configuration before moving to next step
PLC & HMI program and configuration
5. PROTOTYPE
29. Get customer agreement on prototype build and quantity30. Build prototype to customer specifications and time requirements
Prototype panel build
6. BUILD
31. Get customer agreement on expected usage and forecast update process32. Set up supply contract on panel builds
Contract panel build
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© 2015 AWC, INC NextGEN Control System Workbook
APPLICATION NOTES
Application Needs Assessment
Application/Project Overview:
Customer: __________________________________________ Location: ____________________________
Customer Goals: ______________________________________________________________________________
Replace older, hard to get components Reduce Cost Reduce Size Reduce Weight
Add a rating (i.e. Area Classification, Marine, etc.)
Add features:
_______________________________________ _________________________________________
_______________________________________ _________________________________________
_______________________________________ _________________________________________
Other ___________________________________________________________________________________
Commercial Needs:
Customer’s compelling need to change? _____________________________________________________________
Degree of improvement to meet requirements (i.e. reduce costs by 10%): __________________________________________
Time Frame: ______________ for evaluation, _____________ for conversion, _____________ for testing
Expected Volume: ___________________________ Customer Commitment: ______________________________
Tech Partner A: ______________ Expected Sales $_____/yr Tech Partner A Investment: __________________
Tech Partner B: ______________ Expected Sales $_____/yr Tech Partner B Investment: __________________
Tech Partner C: ______________ Expected Sales $_____/yr Tech Partner C Investment: __________________
Panel Layout - Control System & Major Components:
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© 2015 AWC, INC NextGEN Control System Workbook
APPLICATION NOTES
Application Needs Assessment
Programmable Controller:
Small/Simple Application (<100 D I/O & 32 A I/O) Medium Application (<500 D I/O & 200 A I/O)
Large/Advance Application (>200 D I/O & 32 A I/O) Other _______________________________
Remote I/O:
___ No. of Remote Drops ProfiNet Profibus Modbus TCP Other __________________
Operator Interface:
Screen Size:
Features:
Functions:
7” 12” 15” 19” 22” Other ________________
Touchscreen Multi-touch Keyboard Sunlight Other __________
Overview Alarming Trends Help Screen Diagnostics Recipes
Data Management Other _______________________________________________
Controls:
Motor Starter: IEC NEMA QTY/HP/VOLT: __/___/___, __/___/___, __/___/___, __/___/___ Pushbuttons: START STOP E-STOP H-O-A Other ___________________Pilot Lights: ON ALARM Other ______________________
Power:
Voltages: 24VDC 120VAC 240VAC 480VAC 600VAC Other ___________Main Breaker: __ Amps __ kA (Interrupt Rating)
Supplementary Protectors: ___________________CPT (Current Power Transformer): Primary: ___ VAC __ Amps Fused Secondary: ___ VAC __ Amps Fused
Hazardous Area Rating & International Approvals:
Class I: Div 1 Div 2 Zone 1 Zone 2 Class lI: Div 1 Div 2 Zone 1 Zone 2
ATEX: Zone 1 Zone 2 Zone 21 Zone 22 IECEx: Zone 1 Zone 2 Zone 21 Zone 22
Approvals:
Safety:
Safe Mode: Loss of Signal Loss of Power SIL (IEC 61508): SIL 1 SIL 2 SIL 3 SIL 4 Other: ______________________________________________________________________________
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© 2015 AWC, INC NextGEN Control System Workbook
APPLICATION NOTES
Application Needs Assessment
Temperature:
Operating: Low: _____ High: ____ Storage: Low: _____ High: ____
Enclosure:
Rating:Material:Size:Heating:Cooling:EMI/RFI:
NEMA 4 Carbon Steel______H X Heater w/Fan Wall-mounted______________
NEMA 4X 304SS______W X Heater w/o Fan Roof-mounted
NEMA 7 316SS______D Thermo Thermo
IP___ Aluminum Inches _________ _________
__________ __________ mm
Panel Components:
Surge Protector:Grounding Bar:Terminations: Wire Duct Color: Wire Duct Size:Cable Glands:Connectors: Labeling:
Power Supply
Screw Gray_____”H x ____”W NPT NPTWire Ends
I/O____ Push-InWhiteand Metric Metric Terminal Block
Communication
Spring-Cage Blue_____”H x ____”W Ex Ex Wire Duct
Antenna
Other ________
Matl: __________Matl: __________ Devices
Additional:
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
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© 2015 AWC, INC NextGEN Control System Workbook
Control Panel Best Practices
Panel Layout
Mount controller and drive at eye level (Top, left side) Breaker mounted top right Locate SPD (Surge Protection Device next to breaker) Provide enough depth for operator interface, pushbuttons, etc. Spacing: 4” above heat producing items Allow 2” between terminal strips and wire duct
Terminal Blocks & DIN Rail
Discrete I/O: Standard 6mm, gray Analog I/O: 5x20mm Fuse block on one leg, other standard gray Grounding: Grounded to rail, green/yellow 3-wire sensors: triple stack block w/ground Intrinsically Safe: Standard 6mm block, blue Labeling on terminal block Rail Type: Perforated 35mm DIN rail DIN Rail Material: Zinc coated CS 8/32 machine screws
Wire Duct
Size: 3”W x 4”D (if space is available) to provide plenty of space for wiring AC voltage wiring separated from analog wiring with separate wire duct or channel Intrinsic Safe Wire Duct: Blue Label wire duct to identify cables and wire
Enclosure
Type: NEMA 4/4X, unless other requested Material: Carbon Steel (indoor installation); 316SS (outside or for corrosion resistance)
Hinges: Quick Release; hidden hinges for quick access to panel build Lock: Quarter turn latch Back Panel: Zinc plated steel for corrosion resistance
Wiring
Material: Copper, with oil resistant sheathing (UL1015) 24VDC Color Coding: Blue & White/Blue 120VAC Color Coding: Hot = Black; Neutral = White 480VAC Color Coding: Brown, Yellow, Purple Labeling: Both ends of wire at terminal block Shielding: All analog I/O
NOTE: These are suggested best practices. Always follow local (NEC) and international (IEC) electrical specifications.
STANDARDS
© 2015 AWC, INC NextGEN Control System Workbook
Continuous Design and BOM Reviews
APPLICATION ATTRIBUTES Simplifies searching, comparing, maximizing use.
7
REDUCING VARIABILITY
PRE-DETERMINED
INDUSTRY STANDARDS
ENGINEERED SUPPLY CHAIN – BENEFIT vs. COST MANAGEMENT
YOUR APPLICATION
STANDARDS
AWC-INC.COM & DESIGN GUIDE
GUIDES TO KEEP
EVERYONE ON THE
SAME PAGE
www.awc-inc.com
© 2015 AWC, INC NextGEN Control System Workbook
CONTACT US
(800) [email protected]
Subject to change without prior notice
AROUND THE
WORLD AND IN
YOUR BACKYARD!
Working together to win together!
WINNING TOGETHER
AWC’s DESIGN ASSURANCE
• Pre-Engineered Standards• Best Practice Guidelines• Free Technical Support• Free Hands-on Training• Change and Obsolescence
Management• Competitive Pricing• 24/7 Stock Availability• Free UPS Ground ($49+ Orders) • Fully Returnable
WHEN IT’S TIME TO UPGRADE… WE ARE HERE TO HELP
