Integrated, Intelligent

Motor Control Centers

2 Integrated, Intelligent Motor Control Centers

Industry Overview
The goals for any commercial or industrial process are simple:
minimize overall costs and enhance productivity. To achieve these
goals, processes require better monitoring, less downtime, and faster
maintenance. Obtaining real-time process information requires
integrating hardware, software, and communications. Communication
and advanced sensing technologies now exist at the device level, and
recent enhancements make a completely integrated solution both
usable and affordable.

Motor control centers (MCCs) occupy a prominent role in control

schemes, housing a comprehensive array of control and monitoring
devices. MCCs have moved rapidly to include the latest component
technologies and integrating these advanced technologies presents a
major opportunity – to transform islands of data into useful
information that minimizes downtime. This paper focuses on
technology integration methods in MCCs, and quantifying associated
costs and benefits.

Historical Progression
MCC Benefits The benefits of MCCs are well documented and proven by the
approximate $1.5 billion USD global market. These benefits include:

• Quicker installation at a lower cost – with its own power bus and
factory-wired and tested units, field wiring and testing are
minimized.
• Saves floor space – compared to individually mounting the same
devices
• Reduced planning and downtime - standardized sections and
units simplify design and training; plug-in units can be easily
replaced and rearranged
• Expandability – sections and units can be added to existing
MCCs
• Increased level of safety – fault containment is part of MCC
design, and units can be easily unplugged to service at a
workbench, away from hazardous voltages
• Faster delivery – entire system arrives ready to install as a single
entity, with no additional design or components to coordinate
• Serviceable with power ON at adjacent starters – the inherent
isolation of MCC units makes it possible to work on a given unit
without de-energizing any adjacent units, and still conform to
code and OSHA requirements
 Integrated, Intelligent Motor Control Centers 3

Traditional Electromechanical Traditionally, MCCs contained only electromechanical components

Components and all connections were hardwired. These components remain the
workhorses even today, with over half of all MCC units containing
only electromechanical devices.

Solid-State Components Advances in solid-state technology ushered in a revolution in control

systems with intelligent devices that could be programmed to do more
than just turn a motor on and off. These “smart” components found a
warm reception in MCCs, and soon AC drives, soft starters,
programmable logic controllers (PLC“s), and electronic overload
relays were standard offerings in MCC units. Integration was
accomplished through hard wiring to an I/O Chassis.

For a detailed discussion of issues and costs associated with

interwiring in MCCs, refer to Appendix A.

Networked Components The advent of device-level communication networks brought new

possibilities for advanced monitoring, control, and diagnostics. These
networks also greatly simplified wiring, eliminating the bundles of
control interwiring and corresponding complex interwiring diagrams.

Although early MCC network communication brought benefits, there

were also some challenges:

• Reliability and flexibility shortcomings in the “daisy chain”

drop-line architecture connecting units to the main trunk line.
Adding new units or accidental breaks in the chain affected any
downstream units in that connection, potentially shutting down
equipment.
• Safeguarding exposed trunk line and drop line cables in the
wireways, when pulling and installing other power cables.
• Establishing initial network communications with MCC unit
devices.
• Separating power and communication cables to meet code
requirements. In confined wireways, adequate separation was
difficult at best.
4 Integrated, Intelligent Motor Control Centers

Integrated, Intelligent MCC The network communication challenges revealed a need to integrate
the three major system components: the communications, the
hardware, and the software.

These next generation, integrated, intelligent MCCs are current

technology. The design streamlines installation, set-up, and changes;
delivers real-time monitoring of the MCC; and easily integrates into a
facility-wide network.

The questions for today’s users are:

• What is the extra cost to buy an integrated, intelligent MCC?
• What are the real advantages and benefits for my facility vs.
potential headaches and extra cost?
The following section highlights some issues that a user should
consider.

Key Issues To Consider When Evaluating an

Integrated, Intelligent MCC
Different Elements vs. a An integrated, intelligent MCC will contain some different elements
Standard MCC in both the sections and the units, plus software. These can be
categorized as: the built-in communication media, intelligent motor
control components, and MCC monitoring software. Keep in mind
that an MCC may not be an integrated, intelligent MCC, just because
it includes these elements. The early versions of MCCs with
communication networks contained variations of these elements. The
major distinction is that there was not a harmonized design that
deliberately integrated the communication network, hardware, and
software.

A standard MCC ships without interwiring, and requires extensive

interwiring, documenting, and testing in the field. The integrated,
intelligent MCC arrives ready to install, pre-tested and pre-
configured; the communication cables are installed and tested, the
intelligent devices are pre-programmed (with baud rate, node number,
trip current, etc.), and the software screens are pre-configured.

The following sections review important considerations for the

elements outlined above, and provide a framework for evaluating
potential integrated, intelligent MCC offerings.
 Integrated, Intelligent Motor Control Centers 5

Built-in Communication The communication network needs to be analyzed with respect to

Network both the network performance and the physical construction.

• Proven, open communication network – The trend toward open

networks (as opposed to proprietary networks) is clear, and the
advantages are well documented. So how do you choose an open
network? The following criteria form a useful checklist.
DeviceNet is evaluated as an example of an excellent open
network choice.

Criteria DeviceNet

Throughput Up to 500 kbps communication rate

Cost per node Low node cost, due to high

production volume of controller area
network (CAN) chips

Immunity to typical MCC Proven noise immunity (refer to

noise Publication 1485-WP001A-US-P)

Cable rated for use adjacent Both flat and round Class 1, 8A,
to power wiring 600V cabling available

Accepted by a wide range of DeviceNet products are offered by

suppliers and users over 300 suppliers, with over half a
million installed nodes

• Optimized Physical Construction – The obvious approach for

routing network cables in MCCs is through the horizontal and
vertical wireways. Although this method has been successful, the
opportunity exists for a more optimized solution.
•Trunk lines and drop lines isolated behind barriers –
Avoids potential damage to communication cables during
installation and maintenance activities.
•Independent, easy-connect ports on drop lines – The ideal
configuration provides independent ports, readily accessible,
to simplify installing, withdrawing, relocating, and adding
plug-in units. This configuration replaces the “daisy-chain”
architecture, where moving or adding an MCC unit required
interrupting the chain and disabling downstream units.
6 Integrated, Intelligent Motor Control Centers

Droplines behind barriers

or vertical wireway

❑ ❑ ❑

❑ ❑ ❑

Trunkline behind ❑ ❑ ❑ Individual network

barriers ports accessible in
vertical wireway
❑ ❑ ❑

❑ ❑ ❑

❑ ❑ ❑

Intelligent Motor Control To qualify as an intelligent MCC, every unit – even the “non-
Components intelligent” ones - must have communication capability. This is
necessary in order to replace the traditional control interwiring with a
single communication wire. Ideally, all the units should also have
input points to monitor devices like the disconnect switch, contactor,
overload relay, or a hand-off-auto selector switch. A network scanner
module or network linking device must also be provided to collect
and distribute the device data in the MCC. An integrated, intelligent
MCC should have at least the following components available.

• Intelligent overload relays – The most common device in the

MCC is the motor starter, so overload relay intelligence is
paramount. Users should expect:
•Built-in network communication
•Input points (for monitoring disconnect or selector switch)
•Output points (for controlling contactor)
•LEDs for status indication
 Integrated, Intelligent Motor Control Centers 7

•Protective functions – thermal overload, underload, jam,

current imbalance, stall, phase loss, zero sequence ground
fault, and PTC thermistor input.
•Programmable parameters for the protective functions - trip
level, warning level, time delay, and inhibit window. The
ability to program these features avoids the nuisance trips
that often led to users disabling protective functions.
Warning alarms alert users to a potential trip, and allow
actions to avert impending downtime. Time delays and
inhibit windows allow recognition of abnormal current loads
(e.g. extended starting times with high currents), without
nuisance tripping.
•Current Monitoring – phase, average, full load, ground fault,
imbalance percent, and percent thermal capacity used are
important monitoring features.
•Diagnostics – device, warning, and trip status; time to
overload trip; history of last five trips; time to reset.
• Miniature I/O module for non-intelligent units – Traditional
electromechanical starters and feeder disconnects have no means
to communicate with networks. Wiring to a distant I/O chassis is
not the ideal solution. The preferable solution is an I/O module
within the unit – small enough so that the MCC unit size is not
altered - to link the device and the network. The I/O module
should have an adequate number of inputs and outputs, according
to the unit functions. For a starter, four inputs and two outputs
satisfy 99% of applications.
• Network communication interface module with input points –
Intelligent devices often require an external communication
module. Ideally, this module should contain input points (again,
to eliminate wiring to a distant I/O chassis). Four inputs are
sufficient for most applications.

MCC Monitoring Software Integrated, intelligent MCCs have dedicated software that delivers a
window into the motor control center and related equipment. MCC
software eliminates creating costly customized MCC screens within
operator interface software, yielding a “plug and play” solution
usable by computer novices. The following checklist identifies
benchmarks for integrated, intelligent MCC software.

• Operates in a familiar environment – The software will be

easiest to use if it behaves according to known operating
environments, e.g. Windows.
• Includes unique MCC documentation to initialize screens –
Every MCC is unique. The application program, upon
installation, should access specific information to generate
screens containing data pertinent to that MCC.
8 Integrated, Intelligent Motor Control Centers

• Initiates network communication – Establishing devices as

recognized entities on a network can be the most time-consuming
step. In the optimal situation, the MCC manufacturer downloads
user-specific information like node addresses (per user
specification or a standard scheme), and baud rate, then tests the
entire system for accurate functions and communication. Upon
installing the MCC and software, the user only needs to sit back
and let the software poll the pre-configured devices to match the
device information with the user database.
• Displays pre-configured screens showing most common
parameters – Intelligent MCC software can access the user’s
specific data files and build the corresponding screens. The
following pre-configured software screens are useful:
•MCC line-up (elevation) view – Realistic dynamic display
that shows unit type, nameplate information, and status of
units.
•Unit View – Supplies dynamic information about the unit
and network device. Parameters of greatest interest are
already shown, and can be changed if necessary. Data can be
displayed digitally, on meters or trend graphs.
•Event Logging – Automatically logs preset and user-defined
faults and warnings, and accepts manual entries such as
maintenance activities and equipment updates.
•Spreadsheet View – Ideal for viewing the most information
at a glance. Sorting and filtering capabilities help users
organize pertinent data.
• Includes all user-specific documentation – A comprehensive
documentation database minimizes frustration and downtime
experienced while trying to locate misplaced documentation.
Valuable documentation components are:
•Unit wiring diagrams
•As-built drawings of the MCC line-up
•Product user manuals
•Spare parts list
Databases should allow users to add and change information,
especially wiring diagrams.
• Can be accessed at any network level – The user should be able
to view the MCC by plugging into any network level, such as
DeviceNet, ControlNet, or Ethernet. This feature gives the user
flexibility to locate the software on a maintenance laptop, in a
control room, or at an engineer’s desk.
 Integrated, Intelligent Motor Control Centers 9

System Design and Testing Component and systems tests should have been performed, with
demonstrated compliance results readily available. The following
tests assure that integrated, intelligent MCCs will function as
expected and required.

• Design verification tools - Designing networks requires a

thorough understanding of the associated rules and parameters. A
software design tool should be available to verify if critical
network and design parameters have been met. Such software
simplifies the entire design, order, and installation process.
• Electrical and environmental testing - a full battery of tests, both
individual components and when installed as a system include.
•Noise immunity
•IEEE qualification tests
•Showering arc
•Electric drill
•Walkie-talkie
•Overload jogging
•Short Circuit
•UL component and cable qualification
•Shock and vibration
•Seismic
• Completed system testing verify:
•Cable system integrity
•DeviceNet module communication
•Network baud rate and node numbers
•Software content
10 Integrated, Intelligent Motor Control Centers

• Efficiently handles MCC changes and upgrades – MCCs often

have units added and rearranged, so the software must readily
accommodate such data changes. The software should easily
handle new units (with corresponding data information disks),
and any location changes for existing units. Where users must
supply information, step-through "wizards” are the preferred
method, since they guide the process.
 Integrated, Intelligent Motor Control Centers 11

Cost Comparison
How much extra does an integrated, intelligent MCC cost? The
answer requires careful definition of MCC equipment to be compared
in the cost analysis. For example, it is not logical to compare a
standard unwired MCC to an integrated, intelligent MCC.

An appropriate analysis compares an MCC interwired with an I/O

chassis, to an integrated, intelligent MCC. Both are complete
interwired and tested systems, and both provide basic monitoring and
control.

The study evaluates costs for three versions of MCCs: an MCC

interwired to a larger, advanced function PLC I/O chassis; an MCC
interwired to a smaller, basic function PLC I/O chassis; and an MCC
with DeviceNet cabling and necessary DeviceNet hardware. Two
versions of PLCs were used to account for size, function, and cost
differences over a wide scope of PLC offerings. The study consists of
two parts: a variable size analysis that compares costs as the number
of units and sections increases (from 10 starters to 50 starters) with
varying numbers of inputs; and a specific comparison of costs for a
sample representative MCC line-up (eight sections). For simplicity,
the variable size analysis includes one version of a full-voltage
non-reversing (FVNR) starter unit added repeatedly. The sample
representative MCC allows a check on the reasonableness of the
variable size analysis, and is a more realistic representation of a
typical MCC line-up.

General Assumptions for All Cases

• The study only includes actual manufacturer equipment and
wiring costs. Any charges associated with pre-order and post-
shipment activities are assumed common and equal, and are
excluded.
• The study does not include costs for mechanical installation of
MCCs.
• Common costs for all three methods are not included, e.g. wiring
diagrams, any engineering and drafting charges, network
software, PLC programming software, and any dedicated
equipment software. For the study, these costs are assumed to be
common and equal.
• Sections are 20” (508 mm) wide, 15” (381 mm) deep, NEMA
Type 1, with 800 ampere copper main power bus with tin plating,
and a ¼” x 1” horizontal ground bus.
• FVNR starter units contain a circuit breaker disconnect with an
internal normally open auxiliary contact; transformer control; red
and green pilot lights; solid-state overload relay; and one
normally open and one normally closed auxiliary contact
mounted on the starter.
12 Integrated, Intelligent Motor Control Centers

Case 1 Specific Case Assumptions

Class II MCC with a Larger,
Advanced Function PLC I/O
Chassis
Case 2
Class II MCC with a Smaller,
Basic Function PLC I/O Chassis
Case 3
MCC with DeviceNet Cabling
• PLC unit has an eight-slot chassis, power supply, distributed I/O
adapter module, and modules included for inputs and outputs. For
the trend comparison, when the eight slots are exceeded, another
PLC unit is added.
• All inputs and outputs are isolated in accordance with transformer
control in the units.
• 16-input and 16-output modules are included, reflecting typical
user practices. For the trend comparison, when the 16 inputs or
outputs are exceeded, an additional module is added.
Specific Case Assumptions
• PLC unit has a seven-slot chassis, power supply, distributed I/O
adapter module, and modules included for inputs and outputs. For
the trend comparison, when the seven slots are exceeded, another
PLC unit is added.
• All inputs and outputs are isolated in accordance with transformer
control in the units.
• 8-input and 8-output modules are included, reflecting typical user
practices. For the trend comparison, when the eight inputs or
outputs are exceeded, an additional module is added.
Specific Case Assumptions
• DeviceNet cabling is 8 ampere, 600 Volt, Class 1, behind barriers,
with connectors in the vertical wireway.
• DeviceNet nodes are configured.
• Every FVNR starter unit contains a miniature I/O module with 4
inputs and 2 outputs.
• Linking device permits seamless communications from
ControlNet to DeviceNet. No PLC unit is required.
• 8 ampere DeviceNet power supply included.
 Integrated, Intelligent Motor Control Centers 13

Variable Size Analysis

Additional Assumptions

• The process to determine comparative costs consists of: Assume

an initial line-up containing ten (10) size 1 full-voltage non-
reversing starter units in sections, and a PLC unit to
accommodate inputs and outputs. Add Size 1 FVNR starter units
individually up to a total of 50. Include extra PLC units as
required for inputs and outputs. Provide adequate sections to
house all units.
• Six (6) size 1 FVNR starter units per section.
• One output required for each coil.
• Three permutations were performed for the inputs, using two,
three, and four inputs. Inputs are typically used to monitor:
•Contactor
•Overload relay
•Unit disconnect switch
•Hand-off-auto selector switch

The following graphs illustrate the comparative costs for DeviceNet

and Class II MCCs as the number of FVNR starter units increases.
The three Class II lines on each graph correspond to varying numbers
of inputs. Refer to Appendix B for sample data point calculations
used to produce the graphs
.
14 Integrated, Intelligent Motor Control Centers

Cost Analysis for DeviceNet MCC vs. MCC Interwired to a Larger, Advanced Function PLC I/O Chassis

$150,000

$130,000 Smaller jump when

another section is added

$110,000
MCC List Price

$90,000

$70,000
Class II I/O 2 Inputs/Unit

Class II I/O 3 Inputs/Unit

$50,000 Large jump when Class II I/O 4 Inputs/Unit

another PLC chassis
is added DeviceNet w/4 Inputs/Unit

$30,000
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
Total Number of FVNR Starter Units
 Integrated, Intelligent Motor Control Centers 15

Cost Analysis for DeviceNet MCC vs. MCC Interwired to a Smaller, Basic Function PLC I/O Chassis

$170,000

$150,000

Smaller jump when

another section is added
$130,000
MCC List Price

$110,000

$90,000

$70,000

Class II I/O 2 Inputs/Unit

Class II I/O 3 Inputs/Unit
$50,000
Class II I/O 4 Inputs/Unit
Large jump when
DeviceNet w/4 Inputs in Unit
another PLC chassis
is added
$30,000
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
Total Number of FVNR Starter Units
16 Integrated, Intelligent Motor Control Centers

Findings and Conclusions

• The DeviceNet MCC cost is nearly identical to a motor control
center interwired with an I/O chassis. The choice, therefore
should be based on technology preference, not price.
• As expected, the networked solution becomes more cost effective
as the amount of information returned per MCC unit (i.e. number
of inputs) increases.

Representative MCC Comparison

Additional Assumptions • All details listed under both the General Assumptions and the
Specific Case Assumptions apply.
• MCC line-up includes eight NEMA Type 1 sections, with 800
ampere tin-plated copper main power bus, ¼” x 1” horizontal
ground bus, two power bus splice kits, two ground bus splice kits
• FVNR starter unit quantities and sizes:
•(10) Size 1
•(9) Size 2
•(7) Size 3
•(4) Size 4
•(1) Size 5
• Lug provision included for main incoming lines, rated 800A
• Starter units have three inputs (3I), one output (1O)
• Total Inputs – 93
• Total Outputs – 31
• Larger, advanced function PLC requires two I/O chassis
• Smaller, basic function PLC requires three I/O chassis
• MCC with DeviceNet contains a unit with a DeviceNet to
ControlNet linking device and one 8 ampere DeviceNet power
supply unit
 Integrated, Intelligent Motor Control Centers 17

Price Comparison
MCC interwired to MCC interwired to
a larger, advanced a smaller, basic
function PLC I/O function PLC I/O MCC with
chassis chassis DeviceNet
Sections $13,722 $13,722 $13,722
Main lug provision 672 672 672
Starter Units 65,983 65,983 65,983
Network communica- -- -- 21,700
tion interface module
in each starter unit
Power supply unit -- -- 2,400
PLC unit of linking 25,160 31,692 6,000
device unit
Doors 72 108 144
Class II wiring 10,561 11,218 --
Network Cabling -- -- 8,000
Total List Price $116,170 $123,395 $118,621
Prices derived using published list prices

Total Price Comparison for Representative MCCs

$130,000 Communication
interface module,
$120,000
power supply unit,
$110,000 network cabling
Class II wiring
$100,000
Total Price

$90,000

$80,000 PLC or Linking

Device unit
$70,000

$60,000 Sections, splice

kits, Main lug,
$50,000
starter units, doors
$40,000
MCC Interwired to MCC Interwired to DeviceNet MCC
Large I/O Chassis Small I/O Chassis
18 Integrated, Intelligent Motor Control Centers

Findings and Conclusions

The DeviceNet MCC price falls nearly at the midpoint between the
two versions of motor control centers interwired with I/O chassis. The
cost relationships correspond closely to the previous variable size
analysis results.

Summary
Integrated, intelligent MCCs substantially simplify wiring,
troubleshooting, rearranging units, and adding sections and units.
They also provide new information that can be used to minimize
downtime, facilitate monitoring of MCCs and related equipment, and
decrease repair time.With the diminishing cost of intelligence, they
should be strongly considered for all applications.
 Integrated, Intelligent Motor Control Centers 19

Appendix A
Case Study for Factory-interwired I/O Chassis
This white paper uses a factory-interwired MCC as the basis for
comparison to the DeviceNet MCC. Is this valid? Wouldn’t a field-
interwired MCC be a better basis? The factory-interwired pricing was
chosen because it is lower than the price for field interwiring. A
previous white paper documented the price comparisons. An excerpt
follows.

----------------------------

Since 1980, more than 50,000 sections of MCCs have been interwired
to PLCs. The old concern about packaging logic devices in proximity
to high voltage has been sufficiently laid to rest by the overwhelming
success of these installations.

The question still surfaces as to who can interwire MCC units to the
PLC modules most cost-effectively: the MCC manufacturer or a local
contractor/panel shop. A major engineering construction firm wanted
to determine the answer, and conducted an independent study that
evaluated costs of interwiring PLC I/O chassis to motor control center
units. Their study compared costs for both an MCC manufacturer and
an electrical contractor to do the interwiring.

The comprehensive study was based on an actual user order that

needed an MCC and PLC chassis with 320 I/O points, to control a
manufacturing process with 25 motors. The study focused on three
methods for interwiring the motor control center and PLC chassis,
and reviewed costs to supply engineering, design, and construction
necessary to provide, install, and make the equipment operational.
The three methods were:

Case 1
Electrical contractor (panel shop) designs, assembles, and interwires
PLC chassis located in a separate programmable control cabinet to an
MCC.

Case 2
Electrical contractor (panel shop) interwires PLC chassis located in
an MCC.

Case 3
Motor control center manufacturer interwires PLC chassis located in
an MCC, making it a factory-interwired MCC.
20 Integrated, Intelligent Motor Control Centers

General Assumptions for All Cases

• PLC I/O modules included for 160 inputs and 160 outputs.
• All I/O are wired from PLC chassis to terminal blocks – total of
640 wires, 1280 terminations.
• 25 output points are wired from the terminal blocks to motor
starter coils – total of 50 wires, 100 terminations.
• 25 input points are wired from the terminal blocks to motor
starter auxiliary contacts – total of 50 wires, 100 terminations.
• Remaining 270 I/O (135 inputs, 135 outputs) are for field devices
and are located in the MCC for convenience.
• Terminations are pressure-plate type and do not require wire lugs.
• PLC cabinet or MCC sections sized for four I/O chassis (three are
purchased, one future space).
• Hardwired emergency-stop relays and control relays (total of 24)
are wired to terminals, and are located in a dedicated MCC
compartment.
• Internal MCC interlock wiring consists of 48 interlocks (two per
relay) – total of 96 wires, 192 terminations.
• Completion criteria for I/O wired to starters: Each PLC output
shall be energized, the unit control circuit tested, and feedback
from the starter’s auxiliary contact received at the input module.

Services and Materials Provided

Each case included estimates for engineering, drafting, materials, and
installation. Specific case descriptions are identified below.

The following services and materials were provided by others and are
common to all three cases. They are not included in the cost analyses:

Engineering

• MCC single-line diagram and MCC arrangement

• I/O assignments to load and inputs
• Elementary wiring (schematic) diagrams for I/O and hardwired
emergency stop and control circuits
Material and Construction Costs

• MCC incoming power

• PLC programming software
• Wiring from field devices and motors to MCC and PLC I/O
terminals

Case 1
MCC and Separate
Programmable Control Cabinet
Wired by Electrical Contractor
Integrated, Intelligent Motor Control Centers 21
Specific Case Assumptions
• The PLC I/O chassis and I/O terminals are located in a separate,
freestanding NEMA 12 cabinet designed specifically for the
system (to include three I/O chassis with 320 digital I/O).
• The PLC cabinet is located 10 feet (3 m) from the MCC (requires
20 feet [6.1 m] of conduit, 30 feet [9.1 m] of wire).
• Interconnecting wiring between the PLC and MCC will be #14
AWG THHW / THWN copper wire routed in rigid galvanized
steel conduit.
• Five 2-inch (50.8 mm) conduits with (128) #14 AWG wires each,
will be routed between the MCC and PLC cabinet.
• Electrical contractor to wire I/O card wiring arms to the terminal
strips.
Engineering Deliverables
• PLC cabinet layout drawing with bill of material.
• Plan drawing showing location of MCC and PLC cabinet, and
conduit routing.
• Interconnection wiring diagram showing wiring between PLC
and MCC.
• Specify and purchase MCC.
• Specify and purchase labor and materials for interwiring between
the PLC cabinet and MCC units.
22 Integrated, Intelligent Motor Control Centers

Case 2 Specific Case Assumptions

Programmable Controller in
The assumptions are identical to Case 1, except:
MCC Wired by Electrical
Contractor • The PLC I/O chassis and I/O terminals are located in dedicated
sections in the MCC.
• I/O card wiring arms are wired to terminal strips by the MCC
vendor.
Engineering Deliverables

• Specify and purchase MCC that includes I/O chassis, terminal

blocks, and relays.
• Specify and purchase labor and materials for interwiring between
the PLC section and MCC units.
 Integrated, Intelligent Motor Control Centers 23

Case 3 Specific Case Assumptions

Programmable Controller in
The assumptions are identical to Case 2, except:
MCC Wired and Tested by
MCC Manufacturer • MCC manufacturer makes all interconnections between the PLC
I/O chassis and MCC (facotry interwired MCC).
Engineering Deliverables

• Specify and purchase MCC that includes I/O chassis, terminal

blocks, relays, and all interwiring (factory interwired MCC).
24 Integrated, Intelligent Motor Control Centers

Conclusion This independent study shows that Case 3 has the lowest interwiring
cost- i.e. where the MCC manufacturer mounts and wires I/O in the
MCC (factory interwired motor control center).

The study data, combined with other factory interwired advantages -

like reduced start-up time, high quality wiring, and high quality
documentation - support the trend toward increased purchases of
factory interwired motor control centers.

Cost Breakdown - Case Study

Case 1 Case 2 Case 3

Labor Costs
Physical Design of PLC Cabinet and Control Room $ 5250 -- --
2 AutoCAD Drawings-Panel Layout, COntrol Room 2500 -- --
Elec. Design of PLC Cabinet and Interconnection 5000 $ 5000 --
Interdiscipline Coordination, Quality, Management, Drawing Review 2500 2500 --
2 AutoCAD Drawings-Interconnection, Wiring 1680 1080 $ 840
Management, Scheduling, Meetings 1680 1680 1260
RFQ Creation/Analysis 2820 1440 1440
Assembly & Installation of P:LC Cabinet (incl. wiring to terminal blocks) 6284 -- --
Inspection(s) and Travel Expense 3920 1960 1960
Mechanical Installation of MCC 1500 2000 2000
Wiring Between MCC and PLC, Checkout 9570 4836 --
Relay Interlock Wiring 588 588 --
Field Start-Up Assistance‘ 2400 2400 960
TOTAL LABOR COSTS $ 45, 692 $ 23, 484 $ 8,460

Material Costs
Motor Control Center 44436 73992 81391
Enclosure, PLC Components, Terminal Blocks, Panduit, Etc. 24797 -- --
Relays for Safety Interlock 72 72 --
Wiring (and conduit) Between MCC and PLC 1706 276 --
TOTAL MATERIAL COSTS $ 71, 011 $ 74, 340 $ 81, 391

TOTAL COSTS $ 116,703 $ 97,824 $ 89,851

Rockwell Automation provided prices for:

Case 1 MCC and PLC component
Case 2 MCC with PLC (PLC price included in MCC price)
Case 3 MCC with PLC in MCC wired and tested
 Integrated, Intelligent Motor Control Centers 25

Appendix B
Sample Data Point Calculations for Variable Size
Cost Comparison Graphs
The tables show data points used to generate the graphs found in the
Variable Size Cost Comparison section. All prices were derived
using published list prices.

Details about FVNR units, input and output modules, PLC units,
sections, splice kits, and doors are included in the General
Assumptions and Specific Case Assumptions on pages 10-12.

MCC with Larger, Advanced Function PLC

# of # of Inter-
# of # of # of # of PLC # of PLC Unit Section Splice Sub
Input Output Door wiring Total
Units Inputs Outputs Chassis Sections Total Total Total Kit Total
Modules Modules Adder
10 20 10 2 1 1 2 $11,157 $15,260 $3,352 0 0 $29,769 $2,977 $32,746
15 30 15 2 1 1 3 11,157 22,890 5,028 0 36 39,111 3,911 $43,022
2 Inputs per Unit

20 40 20 3 2 1 4 14,762 30,520 6,704 157 72 52,215 5,222 $57,437

25 50 25 4 2 1 5 16,185 38,150 8,380 157 108 62,980 6,298 69,278
30 60 30 4 2 1 6 16,185 45,780 10,056 157 144 72,322 7,232 79,554
35 70 35 5 3 2 7 25,919 53,410 11,732 314 108 91,483 9,148 100,631
40 80 40 5 3 2 8 25,919 61,040 13,408 314 144 100,825 10,083 110,908
45 90 45 6 3 2 9 27,342 68,670 15,084 314 180 111,590 11,159 122,749
50 100 50 7 4 2 9 30,947 76,300 15,084 314 0 122,645 12,265 134,910

10 30 10 2 1 1 2 $11,157 $15,260 $3,352 0 0 $29,769 $2,977 $32,746

15 45 15 3 1 1 3 12,580 22,890 5,028 0 36 40,534 4,053 44,587
3 Inputs per Unit

20 60 20 4 2 1 4 16,185 30,520 6,704 157 72 53,638 5,364 59,002

25 75 25 5 2 1 5 17,608 38,150 8,380 157 108 64,403 6,440 70,843
30 90 30 6 2 2 6 25,160 45,780 10,056 157 72 81,225 8,123 89,348
35 105 35 7 3 2 7 28,765 53,410 11,732 314 108 94,329 9,433 103,762
40 120 40 8 3 2 8 30,188 61,040 13,408 314 144 105,094 10,509 115,603
45 135 45 9 3 2 9 31,611 68,670 15,084 314 180 115,859 11,586 127,445
50 150 50 10 4 2 9 35,216 76,300 15,084 314 0 126,914 12,691 139,605

10 40 10 3 1 1 2 $12,580 $15,260 $3,352 0 0 $31,192 $3,119 $34,311

15 60 15 4 1 1 3 14,003 22,890 5,028 0 36 41,957 4,196 46,153
4 Inputs per Unit

20 80 20 5 2 1 4 17,608 30,520 6,704 157 72 55,061 5,506 60,567

25 100 25 7 2 2 5 26,583 38,150 8,380 157 36 73,306 7,331 80,637
30 120 30 8 2 2 6 28,006 45,780 10,056 157 72 84,071 8,407 92,478
35 140 35 9 3 2 7 31,611 53,410 11,732 314 108 97,175 9,718 106,893
40 160 40 10 3 2 8 33,034 61,040 13,408 314 144 107,940 10,794 118,734
45 180 45 12 3 3 9 42,009 68,670 15,084 314 108 126,185 12,619 138,804
50 200 50 13 4 3 10 45,614 76,300 16,760 471 144 139,289 13,929 153,218
26 Integrated, Intelligent Motor Control Centers

MCC with Smaller, Basic Function PLC

# of # of Inter-
# of # of # of # of PLC # of PLC Unit Section Splice Sub
Input Output Door wiring Total
Units Inputs Outputs Chassis Sections Total Total Total Kit Total
Modules Modules Adder
10 20 10 3 2 1 2 $9,991 $15,260 $3,352 0 36 $28,639 $2,864 $31,503
15 30 15 4 2 1 3 10,982 22,890 5,028 0 72 38,972 3,897 42,869
20 40 20 5 3 2 4 18,364 30,520 6,704 157 72 55,817 5,582 61,399
25 50 25 7 4 2 5 20,973 38,150 8,380 157 108 67,768 6,777 74,545
2 Inputs per Unit

30 60 30 8 4 2 6 21,964 45,780 10,056 157 144 78,101 7,810 85,911

35 70 35 9 5 3 7 29,346 53,410 11,732 314 144 94,946 9,495 104,441
40 80 40 10 5 3 8 30,337 61,040 13,408 314 180 105,279 10,528 115,807
45 90 45 12 6 3 8 32,946 68,670 13,408 314 0 115,338 11,534 126,872
50 100 50 13 7 4 9 40,328 76,300 15,084 314 0 132,026 13,203 145,229

10 30 10 4 2 1 2 $10,982 $15,260 $3,352 0 36 $29,630 $2,963 $32,593

15 45 15 6 2 2 3 18,728 22,890 5,028 0 36 46,682 4,668 51,350
20 60 20 8 3 2 4 21,337 30,520 6,704 157 72 58,790 5,879 64,669
3 Inputs per Unit

25 75 25 10 4 3 5 29,710 38,150 8,380 157 72 76,469 7,647 84,116

30 90 30 12 4 3 6 31,692 45,780 10,056 157 108 87,793 8,779 96,572
35 105 35 14 5 4 7 40,065 53,410 11,732 314 108 105,629 10,563 116,192
40 120 40 15 5 4 8 41,056 61,040 13,408 314 144 115,962 11,596 127,558
45 135 45 17 6 4 9 43,665 68,670 15,084 314 180 127,913 12,791 140,704
50 150 50 19 7 5 10 52,038 76,300 16,760 471 180 145,749 14,575 160,324

10 40 10 5 2 2 2 $17,737 $15,260 $3,352 0 0 $36,349 $3,635 $39,984

15 60 15 8 2 2 3 20,710 22,890 5,028 0 36 48,664 4,866 53,530
20 80 20 10 3 3 4 29,083 30,520 6,704 157 36 66,500 6,650 73,150
25 100 25 13 4 3 5 32,683 38,150 8,380 157 72 79,442 7,944 87,386
4 Inputs per Unit

30 120 30 15 4 4 6 40,429 45,780 10,056 157 72 96,494 9,649 106,143

35 140 35 18 5 4 7 44,029 53,410 11,732 314 108 109,593 10,959 120,552
40 160 40 20 5 5 8 51,775 61,040 13,408 314 108 126,645 12,665 139,310
45 180 45 23 6 5 9 55,375 68,670 15,084 314 144 139,587 13,959 153,546
50 200 50 25 7 6 10 63,748 76,300 16,760 471 144 157,423 15,742 173,165
MCC with DeviceNet

# of PLC # of PLC
# of Units Chassis Sections Total Unit Total Splice Kit Door Total
10 1 2 6,000 22,260 0 0 $33,612
Module with 4 inputs in Unit

15 1 3 6,000 33,390 0 36 $47,454

20 1 4 6,000 44,520 157 72 $61,453
25 1 5 6,000 55,650 157 108 $75,295
30 1 6 6,000 66,780 157 144 $89,137
35 1 7 6,000 77,910 314 180 $103,136
40 1 7 6,000 89,040 314 0 $114,086
45 1 8 6,000 100,170 314 36 $127,928
50 1 9 6,000 111,300 314 72 $141,770

Comparison of Total Costs

% Difference for MCC with % Difference for MCC with

Total for MCC Interwired to Large I/O Total for MCC Interwired to Small I/O
DeviceNet vs. MCC Interwired DeviceNet vs. MCC Interwired
Chassis Chassis
DeviceNet to Large I/O Chassis to Small I/O Chassis
# of Units
Total
3 4 2 3
2 Inputs 3 Inputs 4 Inputs 2 Inputs 3 Inputs 4 Inputs 2 Inputs 4 Inputs
Inputs Inputs Inputs Inputs

10 $32,746 $32,746 $34,311 $31,503 $32,593 $39,984 $33,612 2.6% 2.6% -2.0% 6.7% 3.1% -15.9%
15 $43,022 $44,587 $46,153 $42,869 $51,350 $53,530 $47,454 10.3% 6.4% 2.8% 10.0% -7.6% -11.4%
20 $57,437 $59,002 $60,567 $61,399 $64,669 $73,150 $61,453 7.0% 4.2% 1.5% 0.1% -5.0% -16.0%
25 $69,278 $70,843 $80,637 $74,545 $84,116 $87,386 $75,295 8.7% 6.3% -6.6% 1.0% -10.5% -13.8%
30 $79,554 $89,348 $92,478 $85,911 $96,572 $106,143 $89,137 12.0% -0.2% -3.6% 3.8% -7.7% -16.0%
35 $100,631 $103,762 $106,893 $104,411 $113,192 $120,552 $103,136 2.5% -0.6% -3.5% -1.2% -11.2% -14.4%
40 $110,908 $115,603 $118,734 $115,807 $127,558 $139,310 $114,086 2.9% -1.3% -3.9% -1.5% -10.6% -18.1%
45 $122,749 $127,445 $138,804 $126,872 $140,704 $153,546 $127,928 4.2% 0.4% -7.8% 0.8% -9.1% -16.7%
50 $134,910 $139,605 $153,218 $145,229 $160,324 $173,165 $141,770 5.1% 1.6% -7.5% -2.4% -11.6% -18.1%

Publication Number 2100-WP001A-EN-P — December 2000 Copyright © 2000 Rockwell Automation, Inc. All Rights Reserved.