Strategic Maintenance Brozine_8_6_2008

Filling the Skills Gap
How to Find Technical Talent
As Baby Boomers Retire
strategic
maintenance™

Features
4 What’s New in Maintenance
14 Feature Article
20 Industry Solutions
Maintenance in the Automotive Industry
22 Be Smart About
Intelligent Motor Control
An Integrated Approach to Motor Control and a
Strategic Approach to Maintenance Can Help Maximize
Your Motor Performance and Boost Your Bottom Line
26 Customer Profile
Pepsi Bottling Group
Industrial Design Corporation (IDC)
CENTRIA
38 Tech Tips
Rockwell Automation Support Specialists
Help You Optimize the Performance of
Your Automation Assets
42 QA
Answers to Common Maintenance-related Issues
54 eTools

60 Products, Services Support
100 What’s Next in Maintenance
New Rockwell Automation Products,
Product Improvements and Services Related
to Maintenance That Will Be Available Soon
107 Contacting Rockwell Automation®

Services Support
26Editor-in-chief:
Kevin Oswald (440) 646-5261
kjoswald@ra.rockwell.com
NOTE: Service availability/features may vary by country or region.
As Baby Boomers Retire
strategic
maintenance
62 Assessment Services
66 Condition Monitoring
70 Asset Management
• Asset Management Services
• FactoryTalk®
AssetCentre Software
74 Support
• Remote Support Services
• OnSite Support Services
82 Safety Services
84 Networks Communications
• Network Security Services
• Remote Access Dial-in Modems
90 Training Services
96 Repair Services Renewal Parts
feat u re story :
PRODUCTS,
20
ServicesSupport

4 5
WHAT’S
in maintenance
NEW
4
WHAT’S NEWin maintenance
5
www.rockwellautomation.com/services/safety/
Safety Services
www.rockwellautomation.com/services/repair/inventory.html
www.rockwellautomation.com/services/onsite/
InventoryAssuranceSM
Service
Condition-based Maintenance Mentoring Service
To help reduce downtime when automation equipment fails, it is critical to have
reliable spares on your storeroom shelves. However, spares may not operate correctly
for a variety of reasons:
Broken seals on storage containers•
Environmental exposure (temperature, humidity, vibration, electro static, etc.)•
Extended shelf life•
Unauthorized repairs•
Out-of-date firmware•
Our InventoryAssurance Service gives you the peace of mind that your spares will function properly when needed.
With InventoryAssurance Services, you can send your suspect spares to our certified remanufacturing facilities for
comprehensive inspection and pass/fail testing. If a unit passes all tests and has the most recent firmware updates it
will be returned with a one (1) year warranty. Any unit that fails functional testing and/or requires a firmware update
will be remanufactured to factory specifications using the Rockwell Automation seven step process. Testing fees will
be applied to the remanufacturing cost. All remanufactured units are also covered by a one year warranty.
A minimum of five (5) units is required per InventoryAssurance order.
When you start your predictive maintenance program, it is essential to have the right support and training to
achieve the desired results. With Rockwell Automation Condition-based Maintenance (CbM) Mentoring Service,
you can get the help you need to implement a new condition-based maintenance program
or improve your existing program.
With this mentoring service, Rockwell Automation provides program set-up, all required
hardware/software, support and training. Data collection and analysis is initially performed
by Rockwell Automation. Over the three year service period, these activities
are transitioned entirely to your staff through on-going training (classroom and on-the-job)
and support. This transition is performed according to the following schedule:
1st Year – Rockwell Automation leads analysis•
2nd Year –End-user leads analysis with monthly reviews by Rockwell Automation•
3rd Year – End-user leads analysis with quarterly reviews by Rockwell Automation•
Rockwell Automation now provides a range of Safety Services to help you implement
your safety solution:
Our Arc Flash Services help reduce the risk of employee injury from electrical arc flash/blast and the resulting
release of dangerous levels of heat energy, fire, molten materials, vaporized solids that can be inhaled, flying
shrapnel and rapid expansion of air, all capable of causing severe and sometimes fatal injuries.
Arc Flash Services include:
• Electrical Power Systems Analysis • Overcurrent Protective Device Coordination Analysis
• Arc Flash Safety Training • Hazard Analysis and Mitigation
• Short Circuit Current Analysis • One-line Diagrams
CE Mark Conformity Services
This service makes sure products meet applicable CE marking directives before sale in the European Union.
This service spans 13 elements, including issuance of a Declaration of Conformity (DoC) indicating conformity
of the referenced product to the listed provisions of application directives and standards.
Safety System Validation Services
Validating your safety system performs to design requirements will help you avoid unexpected problems.
This service provides comprehensive tests and analysis to make sure proper system installation and functionality
by evaluating circuit performance, fault tolerance, fault action, software logic, device application, device function
and reset actions for all modes of operation.
Safety Circuit Analysis This service verifies your safety circuit design meets applicable standards. These standards
may include EN-954 Category B,1,2,3, or 4, ANSI B11.TR3 Control Reliable, Single Channel w/ monitoring, Single
Channel, or others you specify. Services include drawing evaluation (and redlining if not compliant for customer’s
revision), re-evaluation of corrected drawings, third party evaluation and letter of conformity to the defined safety
circuit architecture.
Safety Systems Design and Integration Services Rockwell Automation will provide a turn-key safety solution
encompassing a wide selection of machine safety components and services. These services include project
management, system architecture design, panel design, material procurement (including third party
hardguarding products), assembly, software development, hardware/ software integration testing, factory
acceptance and start–up assistance.
Hazard Assessment
A Hazard Assessment identifies safeguarding deficiencies and recommends a machine guarding solution
compliant with current safety standards and designed to meet production and maintenance needs.
Risk Assessment
A Risk Assessment identifies potential hazards associated with a machine or groups of machines, providing a way
to quantify the risk associated with each identified hazard and define the mitigation techniques that could help
reduce high-risk levels to an acceptable level.
Lockout/Tagout (LOTO)Assessment
Complete analysis of your system with recommendations for training, marking/labeling, and hardware to improve
your LOTO process.
Machine Stop Time Analysis
These services include stop time measurements and safe distance calculations to assure compliancy of light
curtain, two hand control, area scanners and safety mat installations. The will also help to determine ergonomic and
operational advantages of safeguarding options.

www.rockwellautomation.com/services/repair/
WHAT’S NEWin maintenance6 7
www.rockwellautomation.com/rockwellsoftware/assetmgmt/assetcentre/
http://forums.rockwellautomation.com/rockwell/
FactoryTalk®
AssetCENTRE Software
Rockwell Automation User Forums
It is becoming increasingly difficult to manage change through configuration
alterations including daily operations like troubleshooting, minor adjustments,
monitoring and temporary patches. Many devices have complex configurations
and sophisticated programs while others can be configured remotely.
FactoryTalk AssetCentre software provides you with a set of asset-centric focused tools to securely and centrally
manage your factory and process automation production environments by securing access to the control system,
tracking users’actions, managing asset configuration files, configuring process instruments, and providing backup/
recovery of operating asset configurations.
The scalable design of FactoryTalk AssetCentre allows for both easier expansion of device counts and extensible feature
sets and provides you an application adaptable to small line applications or enterprise-wide installations. An evolving
set of add-on capabilities, including disaster recovery and instrumentation configuration, extend the FactoryTalk
AssetCentre features.
Rockwell Automation is once again sponsoring an on-line user forum community to aid in self-service support. A link
to the forums can be found on the left navigation menu of Get Support Now (www.rockwellautomation.com/support).
The forums can also be directly by entering http://forums.rockwellautomation.com/rockwell/ into your browser.
Forum features include:
A shared log in with the Rockwell Automation Knowledgebase•
(account registration is administered through the Knowledgebase)
Combined search results for the Knowledgebase and forums•
Potential for automatic support case escalation from automatic support cases•
escalations from forums into the Rockwell Automation case management
system (TechConnect™
Support may be required to receive a response).
24x7 availability•
www.rockwellautomation.com/services/assetmanagement/agreement.html
RepairShieldSM
– ANNUAL REPAIR AGREEMENT
This preventive service allows you to pay a fixed monthly amount for the repair of your automation
assets, helping to stabilize and lower your transactional repair costs. All products sent for repair
undergo the Rockwell Automation seven step remanufacturing process to provide reliable operation
and extend product life. RepairShield also includes repair loop tracking, pareto analysis and probable
cause reports to help simplify repair-related administrative tasks and better understand the reasons
for failure.
Advance Remanufacturing Services
Advance Remanufacturing is a new Rockwell Automation Repair
Services option that provides faster turnaround time than our standard
remanufacturing services (2-3 weeks). With our Advance Remanufacturing
Services, you will receive a remanufactured product from our global
parts hub network within 3-5 days (most products are received within
72 hours). Rockwell Automation will waive the return shipping costs if the
non-warranty failed unit is returned within 15 days.
All products remanufactured by Rockwell Automation undergo our exclusive seven step remanufacturing process.
From proprietary component replacement to firmware updates, quality is ensured at every step to restore failed
units to“like new”or better condition, extending the life of your product, while helping improve its performance
and compatibility.
Rockwell Automation remanufactures repairable Allen-Bradley and selected Reliance Electric products at our
17 global repair centers (all ISO 9000/14000 certified) and has over $100M in products available for exchange
through eight hubs.
www.rockwellautomation.com/services/remote/
Rockwell Automation Receives SCP Certification
for the 10th Straight Year!
SCP is the industry benchmark for service organization excellence. All of our global
support centers providing TechConnect Support are SCP certified, including 10 straight
years for the North America Support Center — the first in the history of the SCP program
to reach this achievement.
SERVICE CAPABILITY PERFORMANCE
STANDARDS
TM
www.rockwellautomation.com/support/directdial/
Direct Dial Codes
Direct Dial is a new phone support feature that allows you to reduce call tree navigation by entering a three-digit code to
directly access Rockwell Automation product support specialists. This new feature is currently available in North America.

www.rockwellautomation.com/services/remote/techconnect/
8 9
PriorityConnectSM
Systems Support
PriorityConnectSM
Support is now PriorityConnect Systems
Support. PriorityConnect Systems Support is the highest level of
service offered through TechConnect Support. PriorityConnect
now offers you an integrated, single point of ownership for
supporting your Rockwell Automation control systems. Your
call will be routed to a select group of Senior Systems Engineers,
experienced in supporting your Rockwell Automation systems.
This group will own your case from your first call to the final
resolution of your issue, including proactive follow-up so that
the resolution meets your satisfaction.
If you have discrete or process automation systems,
PriorityConnect Systems Support will help meet your
support needs:
Highly complex or mission critical processes requiring an•
immediate support response
Lack of internal or local support resources to troubleshoot•
issues at the device level
Lack of internal or local support resources to troubleshoot•
issues after normal working hours
Process system specific issues•
The Enpac 2500 portable data collector and analyzer platform can be configured
to help meet your needs – basic or advanced.
Easier to Use – Light weight, color display, intuitive icon and menu driven navigation•
Faster – Advanced technology speeds navigation and data acquisition•
Rugged – Industrial design withstands the harshest environments•
Scalable – Buy only what you need: Standard single channel instrument, user•
expandable 2 channel, balancing, time waveform recording, etc.
Powerful – Easily connects to our industry leading Emonitor CbM software•
In addition to the above, the new ENPAC 2500 v2.0 now includes these
feature improvements:
Speed reference measurement•
SD memory card support
Append route measurements•
Frequency group labels•
Order tracking•
Time recorder option (add-on module)•
Bump test option (add-on module)•
RU/CD option (add-on module)•
www.rockwellautomation.com/services/training/workstations.html
Training + Starter Workstation
The following five Rockwell Automation ControlLogix®
instructor-led courses now offer the option of being
bundled with a CompactLogix Starter Workstation to improve knowledge retention:
RSLogix 5000 Level 1: ControlLogix System Fundamentals•
RSLogix 5000 Level 1: ControlLogix Fundamentals and Troubleshooting•
RSLogix 5000 Level 2: Basic Ladder Logic Interpretation•
RSLogix 5000 Level 2: Basic Ladder Logic Programming•
RSLogix 5000 Level 3: ControlLogix Maintenance and Troubleshooting•
The Starter Workstation allows you to take your classroom training back to your job and practice/refresh
maintenance and troubleshooting skills in a safer and realistic environment. The 15 lbs. workstation includes
the following:
1 CompactLogix• ™
L31 or L35E processor, 512 memory
1 CompactLogix AC power Supply•
1 Digital combo, 6 digital In/4 digital out•
4 Momentary pushbuttons•
2 Selector switches•
1 Compactbus end cap•
1 Serial port programming cable•
AmeriPak shipping case•
www.rockwellautomation.com/solutions/conditionmonitoring/portable.html
www.rockwellautomation.com/services/training/process.html
PID Loop Development and Tuning
Instructor-Led Training Course
This one-day, introductory course builds the skills needed to obtain a
tuned process control loop for typical applications. You will create and
develop a process model; calculate proportional, integral, and derivative
gains; verify gains using ladder diagram; practice PID programming in
function block diagram and learn how to autotune typical PID loops.
This course allows you to develop an understanding of process control by allowing you to practice PID control
methods for the majority of systems encountered on the job. Although it does not provide you with all skills
needed for every situation, it does prepare you for further process control classes with more specialized
applications and design involvement.
COURSE AGENDA
Creating a Process Reaction Curve•
Developing a Process Model•
Determining the Control Action•
Configuring Program Timing•
Programming a Simple PID Loop Using Function Block Diagram•
Calculating and Verifying PID Gains in Ladder Diagram•
Autotuning a PID Loop•
To view course dates and locations, go to: www.rockwellautomation.com/services/training /schedules.html
ENPAC® 2500 Portable Data Collector v2.0

10 11
www.rockwellautomation.com/services/training/general.html
www.rockwellautomation.com/services/training/clogixcert.html www.rockwellautomation.com/services/training/cbt.html

Quality, Management, Manufacturing,
Safety and Engineering Courses
Rockwell Automation has added over 60 new instructor-led courses to provide a more comprehensive training
portfolio that better meets today’s industry needs. The expanded curriculum complements our existing product
courses and includes the following topics/examples:
• Quality (22 new courses)
- Total Productive Maintenance Fundamentals
- Quick Changeover Implementation
• Manufacturing (18 new courses)
- Industrial Electrical Control Installation and Troubleshooting
- Resistance Welding Controllers Programming and Troubleshooting
• Safety (8 new courses)
- Electrical Safety Awareness
- NFPA 70E – ARC Flash Awareness
• Engineering (7 new courses)
- Design for Manufacturability – Design for Assembly Implementation
- Design for Manufacturability – Machine and Tool Design Implementation
• Management (7 new courses)
- Managers Role in Training Implementation
- Absence Management and Control
Do you need to understand the latest ControlLogix technology? The Rockwell Automation ControlLogix
Certificate Program can help you discover the latest cutting-edge technology and obtain comprehensive
knowledge for use in real-world applications.
Program Objective
This program provides the professional education to help you develop and apply your ControlLogix skills
and knowledge to your plant systems to improve quality, efficiency, and productivity.
Who Should Earn A Certificate
Maintenance or programming professionals who want to stay ahead of the competition, accelerate•
their skills and knowledge using the latest ControlLogix technology and learn how it is applied
Individuals who are responsible for installing, start-up/commissioning, troubleshooting,•
or programming equipment in their plant
Individuals who want to participate in a formal certificate program and obtain the professional•
recognition it provides
Program Requirements
Registration is not required for this program. Participation is voluntary and self-guided. You will
complete a series of three required ControlLogix courses related to your maintenance or programming
job responsibilities, plus one course elective. Refer to the curriculum maps on page 92 for course details.
After completing the courses, you complete an online assessment to confirm your ControlLogix knowledge.
To earn the ControlLogix certificate, the program requirements must be completed within 12 months.
Contact your local Rockwell Automation sales office or Allen-Bradley distributor to enroll in the Certificate
Program courses and final assessment.
After completing the Certificate Program requirements, you will receive:
ControlLogix Certificate of Achievement•
Rockwell Automation Shirt with Certificate Program Emblem•
ControlLogix Job Aids•
CEUs (Continuing Education Units through IACET)•
Coupon for 50% Off One RSLogix 5000 Computer-based Training Program•
Coupon for 10% Off One Additional ControlLogix Course•
Other Special Offers to Certificate Holders Only•
The RSTrainer® for RSLogix™
500 bundle is an interactive series of computer-
based training courses through which you will learn the core tasks required to
effectively program and troubleshoot an RSLogix 500 project. Purchasing the
following self-paced courses together as a bundle will save 18% compared
to the price of purchasing them separately:
• RSTrainer for RSLogix 500 Software-Offline Programming
RSTrainer for RSLogix 500 – Online Monitoring•
RSTrainer for RSLogix 500 Software – Documenting and Searching•
Each course includes a variety of learning tools and resources including animations, background information,
interactive simulations and links to other reference materials. These tools and resources, combined with the
step-by-step demonstrations, will provide the knowledge required to perform each job task.
RSTrainer for RSLogix 500 Software Training Bundle ControlLogix Certificate Program
Certificate Program
C o n t r o l L o g i x
www.rockwellautomation.com/services/training/cbt.html
RSTrainer Student Manager Enterprise Edition
Managing employee skills in a global environment can be difficult. For multiple users and concurrent classes,
the RSTrainer Student Manager Enterprise Edition will provide a tracking and reporting utility for any number
of courses and students. Companies of all sizes find this network solution to be a great way to manage and use
the RSTrainer self-paced suite of courses. Select RSTrainer Enterprise Edition to deliver online training and have
the flexibility to track and manage students’online training activity from any location.

www.rockwellautomation.com/knowledgebase/
www.rockwellautomation.com/services/onsite/
www.rockwellautomation.com/services/training
Contract CallOut Services
Fundamentals Training + One
Help reduce your maintenance expenses by prepurchasing Rockwell
Automation Callout Services at a major savings over standard hourly
rates. Contract Callout Services can be used for a wide range of
OnSite Support Services, and by prepurchasing, you won’t need
additional approvals or purchase orders to request a service call.
Fundamentals Training + One is a great way to extend your learning experience beyond just the basics and save
money in the process. Enroll in any Rockwell Automation Fundamentals class and receive a $350 USD discount
(or use one less training voucher) on your next class if you enroll within 30 days.
www.rockwellautomation.com/solutions/maintenance/ and www.rockwellautomation.com/solutions/migration/
The Rockwell Automation Knowledgebase is your first resource
for technical information and support, available online 24x7x365.
This tool helps you increase your productivity by providing
solutions to technical questions more quickly – saving both
time and money. To optimize user experience, the
Knowledgebase interface has been redesigned and
many new features have been added including:
Multiple search options•
Product•
Category (e.g., patches, release notes, obsolescence notices)•
Keyword (artificial intelligence allows use of natural language)•
Custom (create and store your own search profile)•
Weekly change notification e-mail (based on your product, category or other information preferences)•
“Ask a Question”• 1
– submit online support questions directly to Rockwell Automation technical support specialists
1
Available to customers with a TechConnect Support or ESAFE® Support contract
MAINTENANCE, MIGRATION SOLUTIONS WEB SITES
These two new web sites will help you determine the right maintenance and migration strategy based on the
unique needs of your company. They also help identify the Rockwell Automation Services Support offerings you
can leverage to make the appropriate maintenance and migration decisions and properly implement your chosen
solution to achieve the desired results.
www.rockwellautomation.com/services/repair/
PanelView 1400 and 1400e LCD Upgrade
Upgrading your PanelView™
1400 or 1400e Operator Terminal’s CRT to a Liquid Crystal
Display (LCD) Flat Panel is an excellent option to extend the life of your current investment
and take advantage of LCD Flat Panel technology. If you are not prepared to move to the newer
Rockwell Automation visualization products, the LCD upgrade may be the right decision for your plant.
By choosing Rockwell Automation to perform your upgrade, you receive these exclusive benefits:
LCD Flat Screen Technology Factory approved Industrial Grade LCD technology designed to help meet the
demands of your automation environment
Design Internal replacement hardware designed to integrate seamlessly into the original product design
Testing Factory approved testing procedures that makes sure PanelView meets original design quality requirements
Support Remote technical support for your upgraded PanelView is provided through a new or existing TechConnect
Support agreement.
The PanelView LCD upgrade is available through Rockwell Automation Repair Services (in the U.S., call 440-646-3434,
option 2). Outside U.S., call your local Rockwell Automation Sales Office).
www.rockwellautomation.com/solutions/conditionmonitoring/
Dynamix Integrated Condition Monitoring PRODUCTS
Rockwell Automation will now market its existing family of condition monitoring
products under the name Allen Bradley® Dynamix™. This family includes products
for machinery protection and predictive maintenance applications. Some of the
products currently in the Dynamix family include the XM 120/160/320 Intelligent
I/O Modules, Enpac 2500 Data Collector, Sensors/Probes, and Emonitor software.
Improved Knowledgebase Interface and Functionality

f e a t u r e a r t icl e
14
The Numbers
Revenue
By Blake Moret
Vice President,
Customer Support Maintenance
Rockwell Automation
All these factors have created a drought
of skilled labor. The good news is that
you have options for attracting and
retaining a skilled labor force.
1515
In October 2007,
the first Baby Boomer applied for Social Security
benefits in the United States. Kathleen Casey-
Kirschling was born New Year’s Day 1946, at one
second past midnight, making her the first baby of
a new generation. Her application to receive Social
Security benefits signals the beginning of a drain on
skilled workers that will result from the retirement of
millions of Baby Boomers worldwide.
You are likely already feeling the impact of these
retirements, as experienced engineers exit the
workforce in droves and skilled replacements are
difficult to find.
In addition, technology advances have impacted every step of the manufacturing process,
from design to production to inventory management, delivery and service. Manufacturing jobs
are now technology jobs, and employees must have skills required for today’s workplace.
These competitive mandates put a high premium on the skills, morale and commitment of workers,
and has created a drought of skilled labor. The good news is that you have options for attracting and
retaining a skilled labor force.
Anyone working in manufacturing knows about this skilled
worker shortage, but most of the general public does not –
even though the numbers tell the story.
The U.S. Department of Labor forecasts that by 2012 the
U.S. economy will have the largest workforce in the nation’s
history – more than 162 million people. However, it will not be
enough to fill the more than 165 million jobs that are projected
to be available.
Eighty one percent of respondents to the Manufacturing
Institute/National Association of Manufacturers (NAM) 2005
Skills Gap survey said they could not find qualified workers to
fill open positions. 83 percent of manufacturers indicated that
shortages are affecting their ability to meet customer demands,
with more than half reporting difficulty achieving necessary
production levels and 43 percent reporting difficulties
increasing productivity.
The report predicts that by 2020 the U.S. manufacturing
industry will need up to 10 million new skilled workers. Even
though Asia and other developing areas generate four times
the number of engineering students, companies can’t address
the gap between worldwide staffing needs and the number
of qualified production employees in the labor pool.
Four areas in particular will suffer a mass departure of
employees: health care, manufacturing, energy and the public
sector, according to the 2003 NAM/Deloitte report,“Keeping
America Competitive: How a Talent Shortage Threatens U.S.
Manufacturing.” U.S. manufacturers face a shortage of qualified
machinists, craft workers and technicians. Manufacturers are
competing for talent from the same workforce pool that other
industries are tapping.
According to estimates by ISA – The Instrumentation,
Systems, and Automation Society, at least 200,000 automation
professionals work in the United States. Based on an estimated
5 percent per year retirement rate, plus a 3 percent annual
growth rate for the profession, that means 8 percent of those
200,000, or about 16,000 new people, will be needed each year
in the future. The annual need for automation professionals will
exceed the supply in the pipeline today.
Filling the Gap
As Baby
Boomers Retire

16 17
One of the biggest challenges affecting the shortage is the
Baby Boom retirement wave. Baby Boomers, born between
1946 and 1964, start turning 62 in 2008 – the average
retirement age in the developed economies of North America,
Europe and Asia. During the next 15 years, 80 percent of the
workforce growth in these continents will occur among people
50 years or older, according to the 2004 “HRI Fortnight Report”
from Eurostat.
The Baby Boom retirement wave will strongly affect Europe
because of low birth and immigration rates, according to
the Deloitte research report “It’s 2008: Do You Know Where
Your Workforce Is?” With increasing pension obligations and
shrinking workforces, Germany, Italy, Spain and Japan could
face economic hardships.
In China, the government’s policy of allowing couples to
have only one child has led to a deficit of skilled workers,
especially in urban areas. By 2050, 40 percent of Europe’s
total population and 60 percent of its working-age population
will be comprised of people over age 60, according to the
Eurostat report.
According to U.S. Census Bureau projections, a substantial
increase in the number of older people – retirement age –
will occur from 2010 to 2030. The older population in 2030
is projected to be twice as large as in 2000, growing from 35
million to 72 million. This segment will represent almost 20
percent of the total U.S. population in just 23 years.
Additionally, an AARP report, “The Business Case for Workers
Age 50+,” prepared by Towers Perrin, found that human
resources managers who may have once thought that older
workers could be replaced by younger workers fresh out of
school will find themselves creating flexible work schedules,
telecommuting options, training and education, phased
retirement and“bridge jobs”expressly designed to encourage
workers over age 50 to remain on the job beyond the age at
which they might otherwise retire.
Without changed management practices, millions of jobs
could go unfilled because there will be a shortage of workers
who have the specialized skills required to fill the vacancies.
Skills Gap and Education
The Manufacturing Institute/NAM Skills Gap survey highlights
the shortfall of highly qualified employees with specific
educational careers. Educational trends are exacerbating
the situation. In the United States, Germany and Japan, for
example, the percentage of students graduating with science
and engineering degrees is in the single digits, far below the
percentages for India and China, according to the 2003 Deloitte
report. In the United States, colleges will graduate only 198,000
students to fill the shoes of 2 million Baby Boomers retiring
between 1998 and 2008, according to NASA projections.
Declining student interest and failure to encourage young
people to pursue manufacturing careers is a significant
factor. This is largely affected by the general public’s outdated
perceptions of manufacturing jobs’working conditions
and compensation. Too few students in large, developed
economies are pursuing science and engineering. About 42
percent of students in China earn undergraduate degrees in
science and engineering, but only 5 percent of U.S. students do
so, according to a July 2004 article in The Wall Street Journal. In
Germany, the number of engineering graduates has declined
by almost a third since 1995, to about 36,000 – one-tenth the
number produced by Chinese universities, the article notes.
The irony is that because of technology advancements, the
level of education required for blue-collar jobs is higher than
ever before. For example, tool and die makers must have four
to five years of apprenticeship training after high school. They
need to master algebra, geometry and trigonometry, as well as
possess technical reading skills. Unfortunately, a recent study
by the Society for Human Resource Management (SHRM)
found that half of survey respondents said they are seeing
many new workers who lack overall professionalism, written
communication skills, analytical skills or business knowledge.
The Baby Boom HitsLeveraging Rockwell Automation
Services Support to Fill Your Skills Gaps
In the United States, colleges will graduate only
198,000 students to fill the shoes of 2 million
Baby Boomers scheduled to retiring between
1998 and 2008, according to NASA projections.
The right maintenance strategy will help you optimize the performance
and utilization of your automation assets throughout their life cycle –
helping reduce downtime, improve operation to spec, reduce speed to
change – and ultimately – improving your financial stability (both through
lower maintenance costs and increased productivity).
The success of your maintenance strategy is based primarily on two
factors – people and equipment. While these may seem equally
important, people often make the difference. People are required to
design systems with the right equipment and develop the right strategy
to maintain the system. People also need to execute that strategy –
consistently throughout the entire life of the system.
However, many companies are finding it increasingly difficult to find these
people. Baby Boomer engineers and technicians are retiring – in droves.
Technical schools and universities are not supplying enough graduates
to replace them. To fill this technical skills gap, companies have employed
many strategies, one of which is to leverage the services of automation
suppliers like Rockwell Automation.
Rockwell Automation offers a complete portfolio of Services Support
(left, pages 60-99) to both train your staff and provide supplemental
automation professionals to augment your internal resources.
Rockwell Automation Services Support are delivered through an
integrated, global network of remanufacturing facilities, exchange hubs,
onsite support dispatchers, training classrooms, technical phone support
centers, and online tools. Rockwell Automation is committed to the
long-term investment in this services infrastructure, facilities and people,
to help meet ever-changing customer needs. This investment can take
many forms. It includes opening a new remanufacturing center in a
growing region (as we recently did in Shanghai, China), achieving SCP
certification at all of our technical phone support centers, and launching
new or expanded services (including over 60 new training classes, see
What’s New section). Investments in our people include formal, on-going
training programs for our services professionals so that they have the
appropriate knowledge and skills to maintain your automation equipment
and systems.
Rockwell Automation Services Support can be purchased on an
as needed basis or through an annual contract. Many companies
increasingly rely on service contracts to make sure technical resources are
available when needed and to help reduce/stabilize their maintenance
costs. To see how Pepsi Bottling utilized Rockwell Automation Services
Support to lower their costs, see page 26.
Filling the Gap

TheTimeisNow
The skills gap created by retirements is already open and quickly expanding in many parts of the world.To fill the gap,
companies must proactively identify and implement ways to find and retain the technical skills required to meet their
production requirements – whether in the form of full-time employees or through the resources and services of companies
like Rockwell Automation.
Your strategy for finding these skills will likely depend on the size of the gap you are currently experiencing. If you have had
many retirements in recent years, you may need to rely on a service organization more – unless you began to train younger
workers well in advance of retirements so they could adequately replace older staff that left the workforce. Even if you’ve taken
this approach, younger workers with 3-5 years of experience may still struggle to perform the same duties as someone with
25-30 years of experience. In this situation, Rockwell Automation is often leveraged to provide additional training, remote
support or experienced field service professionals to augment the skills of internal maintenance and engineering staffs.
No matter how large your skills gap, the key to successfully overcoming it is proactively identifying and implementing the right
strategy to narrow or close it. Failure to do so could result in an endless struggle to maintain a consistent production environment
that meets corporate goals and customer expectations.
18
You can conduct an Internet search and find thousands of
programs offered by colleges, local and state governments,
associations and trade shows. In addition to proactively getting
involved in activities such as these, you have many other options
to fill your workforce gaps.
An important step is to take advantage of the services that your
suppliers offer. According to the ARC Advisory Group study,
“Automation Supplier-Provided Services: Market Size and Forecast
Through 2011”www.arcweb.com/res/autosvs, the lack of skilled
labor is a primary factor in increasing user demand for automation
services – especially maintenance services – for nearly all
automation products and applications. Many manufacturers can
no longer perform automation services in-house.
Suppliers, including automation companies such as Rockwell
Automation, offer you services and solutions that can be leveraged
to help increase the experience of your employees and ramp
up productivity and profitability with fewer resources than ever
before. These services offer specialized experience across a range
of technical domains, such as process, safety, networks and
sustainability.
Technology-enabled services can help you implement programs
that provide consistent quality and production levels across the
globe. For example, remote monitoring allows companies to
allocate their limited worker resources where they’re needed.
Services like these bolster the bottom line because of decreases
in downtime. Quality is affected as well; problems that can go
unnoticed by busy operators are caught by remote engineers who
understand the customer’s process for any deviation from normal
operating parameters.
Another important step in filling the technical skills gap is to
realize that recruiting talented workers is no longer just a
human resources issue. Competitors can easily match rich
compensation packages and“hot skills”bonuses. Today’s talent
pool is motivated by more than just having a job; they want
opportunities to continuously learn, to be challenged, to take on
more responsibility and to contribute to the overall health of
the organization.
This also means you must rethink the ways you manage people.
Identify the segments of the workforce that drive your growth.
Then, rather than just focusing on metrics and outcomes
(“acquisition”and“retention”of personnel), concentrate on
determining the right combination of internal and external
resources to meet your everyday technical needs as well as
execute more strategic maintenance, asset management and
system optimization activities to maximize the return on your
automation investment.
What are Companies Doing About It?
What Can You Do?
On many local, statewide and regional levels, grassroots activity
to address this problem is growing. Some manufacturers are
starting their own community initiatives to develop and obtain
skilled workers. For example, Gonzales Manufacturing, owned
by Cleaver-Brooks in Gonzales, Texas, is a provider of boiler
room systems. The company partnered with nearby Victoria
College to create a training class for welders. This hands-on,
accelerated evening course has been well received. Victoria
College also is creating a satellite campus near Gonzales’facility
to serve a variety of training needs.
Industry associations are trying to help. The National
Institute of Metalworking Skill (NIMS, www.nims-skills.org) is
a consortium of metalworking trade associations, national
labor organizations, council of state governors, companies
and educators developing skill standards and credential
assessments. It offers educational training programs based on
NIMS skill standards. By the end of 2006, the group awarded
13,383 credentials, with 162 accredited programs in operation.
The“Dream It. Do It.”campaign (www.dreamit-doit.com)
was developed by NAM and The Manufacturing Institute,
NAM’s research and education affiliate. The program targets
the 18-26 age group to recruit and train the next generation
of workers in science and math, helping young adults find
careers that they can be passionate about in manufacturing.
Whether someone is interested in cars, computers, music or
art, the initiative demonstrates that there’s a great job waiting
for him or her in manufacturing.
Industry expositions also are playing a part. The NIMS
Student Summit at the biennial International Manufacturing
Technology Show (IMTS, www.imts.com) is a good
example. Educators, career guidance counselors and school
administrators can join their students to examine machines
at the expo. Through the Student-Friendly Exhibitors and
the Career Awareness Area, students get a look at a variety
of career opportunities available in today’s sophisticated,
high-tech manufacturing industry. Teachers and their students
consistently experience a positive change in their perceptions
of careers in manufacturing.
The FABTECH International and AWS Welding Show (www.
fmafabtech.com) features an annual job fair and Workforce
Development Pavilion. Employers can meet and possibly
recruit from a pool of thousands of welding and sheet metal
fabricating professionals attending the event.
Local communities, industry associations,
and service organizations are helping to fill the
technical labor pool with more skilled workers.
Filling the Gap
For more information on the Rockwell Automation Services Support that
can help you fill your skills gap, go to: www.rockwellautomation.com/services
19

To determine the
right combination of
maintenance methods to
apply to your automation
assets, a variety of factors
should be considered:
Asset Type/Function•
Utilization/Capacity•
Life Cycle Phase•
Staff/Personnel•
Requirements
Impact on Quality•
and Revenue
Average Cost of•
Unplanned Downtime
If your primary
maintenance method
is predictive or preventive,
some elements of a
reactive approach will
still be required. A
predictive approach
will also include some
elements of a preventive
approach. The automotive
assembly plant shown
provides an example of
how different approaches
may be applied based
on the above factors.
The situations are
hypothetical and may
not apply to your facility.
Strategic maintenance in the AUTOMOTIVE INDUSTRY
20 21
Tier Supplier
Problem: Today’s tier supplier to the
automotive industry must deliver their
products to the assembly plants on time and
in sequence. In addition, quality data for
each part or lot must be provided at the time
of delivery. Today’s manufacturing systems
rely on comprehensive and sophisticated
communications systems to coordinate
production, identify problems early to help
prevent costly downtime, and collect the
necessary data to satisfy the end customer’s
product quality and warranty requirements.
Changes to the products or processes
can adversely affect the reliability of the
communications network infrastructure.
Proper Maintenance Approach
A predictive/preventive approach that
includes Rockwell Automation Network
Services will help you evaluate your current
and future network needs and design /
validate/maintain a fully integrated
communications network with the speed,
volume and other functionality required
of today’s more sophisticated and complex
industrial automation and control
environments. For more information on
Rockwell Automation Network Services, go
to page 84 or www.rockwellautomation.com/
services/networks.
Press
Problem: Metal stampings for cars and light trucks are
produced in the harsh environment of large press shops with
multiple presses and welding lines producing thousands of
parts per hour that are fed directly into the assembly process.
These shops typically have a very wide variety of complex
machines and spare parts inventories for them can be large
and expensive. Due to the harsh environment in which
these machines operate, machine downtime due to failed
components can and will occur at the worst time – making
it critical to have the right spare parts on hand to maintain
production.
Because of the increased potential for equipment failure, and
need for automakers to reduce operating costs, a preventive
approach that includes proactively managing your MRO
process and spare parts inventory, as well as scheduled
maintenance, should be utilized. This approach will help reduce
unplanned downtime, extend equipment life, and minimize
repair and carrying costs – increasing RONA (Return on
Net Assets) and OEE (Overall Equipment Effectiveness). A
Rockwell Automation Parts Management Agreement (PMA)
will make sure the appropriate spare parts are on hand for a
fixed monthly or quarterly cost. A Rockwell Automation Asset
Management Portfolio (RAAMP) will provide an on-site Asset
Management Professional to implement our MRO process
methodology. This methodology simplifies repair transactions,
tracks warranties and identifies recurring reasons for failure to
help meet associated key performance indicators (KPI)
defined by you. For more information on Rockwell
Automation Asset Management Services, go to page 70 or
www.rockwellautomation.com/services/assetmanagement.
Body Shop
Problem: Automotive body shop welding
operations are typically the most advanced and
automated processes in the vehicle assembly plants
today. More and more robots are being employed
in this section of the plant and with that comes
increased potential for safety risks. Traditional
lockout/tagout (LOTO) methods of protection
are effective safety procedures, but can hinder
overall productivity and throughput in the complex
manufacturing processes employed. Additionally,
safety standards and regulations continue to evolve
requiring re-evaluation of the existing safety systems.
Recently developed global safety standards and
technologies have made manufacturing safety a
powerful tool to achieve both workplace safety and
production capacity improvements. A preventive
approach that includes proactive implementation
of these standards and technologies not only
helps reduce the risk of injuries; it provides major
improvements in manufacturing productivity and
efficiency through improved Overall Equipment
Effectiveness (OEE). For more information on
Rockwell Automation Safety Services, go to page 82
or www.rockwellautomation.com/services/safety.
General Assembly
Problem: The Trim-Chassis-Final
(T-C-F) portion of the assembly plant is
comprised of a large collection of specialty
machines set up in sequence to complete the
vehicle assembly. Each of these machines has
their own unique processes, components,
operations and controls. Downtime incurred
on any of these machines will shut down the
entire T-C-F shop. It is a daunting task for
maintenance staffs to ensure uptime on all of
these unique systems, but the profitability of
the plant depends on it.
To improve your job performance and the
performance of your automation assets, you
need to implement a preventive approach
that includes successfully obtaining the right
technical knowledge and ability to apply
it when required – from installing new
equipment to maintaining an existing system.
Rockwell Automation Training Services will
help you achieve this goal. Our performance-
based training methodology provides the
right combination of traditional instruction,
hands-on practice, and refresher exercises
to maximize your subject matter retention
and successfully utilize that knowledge day
after day. To meet a wide variety of learning
needs, standard, tailored and custom classes
are available on over 300 automation, general
industrial, management and other related
topics. For more information on Rockwell
Automation Training Services, go to page 90
or www.rockwellautomation.com/services/
training.
Paint
Problem: Monitoring and controlling
the emissions of volatile organic compounds
(VOC) are critical to the continued operations
of today’s modern paint shop. These systems
employ large, electric-motor driven fans and
pumps that must run 24 x 7. They are typically
located in areas of the plant with limited access.
Any unplanned downtime of these critical
components will quickly shut down the entire
assembly plant.
A predictive approach utilizing condition
monitoring will provide the data you need
about critical motors and other rotating
equipment to identify problems before a failure
occurs (or automatically shut down equipment
should safety or other factors be an issue). You
can then schedule downtime to correct the
problems when it will least affect production
and required labor and materials are available.
For more information on Rockwell Automation
Condition Monitoring Products and Services,
go to page 66 or www.rockwellautomation.com/
services/conditionmonitoring.
All Production Areas
Problem: All areas of production experience automation-related problems that need to be corrected, even those with a predictive and/or preventive
maintenance approach. However, the success of the corrective action can be affected by many factors including maintenance staff availability and experience,
spare parts availability and access to equipment.
Proper Maintenance Approach Regardless of other maintenance approaches in place, a reactive approach will always be necessary in each
production area. Sometimes it may be the only maintenance approach depending on the criticality of the equipment, its age, cost to repair and other
factors. Rockwell Automation Remote Support, OnSite Support, and Repair Services offer multiple service options to address your reactive maintenance
needs. Allen-Bradley Remote Access modems also provide a cost effective solution for your maintenance staff to remotely connect to control systems to
check system status, make programming changes, update firmware and more. For more information, go to www.rockwellautomation.com/services.

You areunder constant pressure to lower maintenance costs, increase flexible production and response
speed, and lower energy costs. One area that can provide you with benefits in all these areas is motor control. In most plants,
motors are the largest asset and use the largest percentage of energy. Therefore, protecting motors is vital to productivity
and profitability.
Contained within a motor’s temperature, vibrations and other operating data are clues to pending shortcomings that can
cause profit-crippling effects. An integrated, intelligent approach to motor control and maintenance incorporates the best
predictive, preventive and reactive maintenance technologies and strategies to positively impact the bottom line.
With its networked Intelligent Motor Control and maintenance experience, Rockwell Automation engineers can help you
integrate predictive condition monitoring technology to help improve production metrics and lower the total cost of bringing
a product to market. Solutions include variable frequency drives, electronic overload relays, soft starters, packaged and
pre-engineered solutions along with condition-based monitoring capabilities.
I n t e llig e n t M o t o r C o n t r o l
An Integrated Approach to Motor
Control and a Strategic Approach
to Maintenance Can Help
Maximize Your Motor Performance
and Boost Your Bottom Line
AboutBe Smart
Many who want to help avoid maintenance-related downtime
use networked intelligent motor control devices. These devices
provide timely, accurate data on critical operations so you can
develop comprehensive maintenance programs that employ
predictive, preventive and reactive elements.
CENTERLINE® Motor Control Centers (MCCs) with IntelliCENTER®
technology seamlessly integrate your control and
communications into one centralized motor control package.
IntelliCENTER® software works with intelligent motor control
devices, allowing you to monitor loads, use data trending
information for predictive maintenance and access electronic
documentation. IntelliCENTER software provides
the ultimate window into CENTERLINE low and medium
voltage MCCs.
With condition-monitoring tools such as the Allen-Bradley
Dynamix XM® machinery protection and condition-monitoring
modules, maintenance engineers virtually can be at all points
on the pipeline at once. The XM series can be deployed as
either a stand-alone monitor or as part of a broader network
solution that detects machinery deterioration. This helps
operators and maintenance departments correct issues before
productivity is affected.
The modules can be integrated via open networks with
programmable controllers, distributed control systems
(DCSs), plant display and visualization and condition-
monitoring systems.
Condition-monitoring information helps engineers develop
maintenance schedules based upon the actual or predicted
condition of rotating assets.“Planned”maintenance helps
reduce maintenance spending and increases the asset’s
availability for production, while helping to reduce spare
parts inventory.
Intelligent, networked electronic overload relays such as the
Allen-Bradley E3 Plus, can process critical parameters that can
be used to assess motor health, help predict the future health
of motors, and give engineers valuable operating information.
How Intelligent Motor Control Helps
22 23
Without opening unit doors, IntelliCENTER software
allows real-time, remote monitoring, configuring and
troubleshooting of both low and medium voltage
CENTERLINE Motor Control Centers (MCCs) with
IntelliCENTER Technology. Using Intelligent motor
controls, IntelliCENTER Technology can warn of
failures before they occur – allowing you to react with
a safe, orderly response to unexpected situations.
You can diagnose or troubleshoot your drive and access
detailed fault, alarm and event information directly with the
RSLogix™ 5000 software.
Maintenance-related Software Features for Intelligent Motor Control

By applying a strategic approach to maintenance and using the diagnostic
capabilities of Intelligent Motor Control solutions you can help improve the
performance of motor control equipment to reduce the amount of time
necessary to install, maintain and repair your motor control equipment.
The Rockwell Automation approach to helping reduce drive configuration
time is found in Premier Integration – RSLogix 5000 v.16 software with
PowerFlex® drive add-on profiles. With it, users of Allen-Bradley PowerFlex
drives can consolidate drive system configuration, operation and
maintenance into a single environment. This helps reduce programming,
installation and overall ownership costs by minimizing the number of
required software tools, providing faster start-up, improved accuracy and
easier drive-system maintenance. A valuable Premier Integration feature that
directly affects maintenance is found in the FactoryTalk® (RSView®) PowerFlex
faceplates. These faceplates can provide detailed alarm information and
corrective action, rather than only an error indicator or code number, cutting
down on troubleshooting time.
With Premier Integration you have a central software platform that
seamlessly integrates motor control into your manufacturing application
along with access to detailed alarm information that can help get you back
up and running faster.
To help prevent mechanical damage to your motors, PowerFlex AC drives
offer current-limiting functions that are used to control the amount of
current an AC drive supplies to a motor, and therefore the torque the motor
produces. The current-limit level may be adjusted to effectively limit the
motor torque. Even if the process controller is asking for higher speed from
the drive, the current limit will not allow the drive to output more current
than the limit.
Most Allen-Bradley drives also have a feature called an electronic shear
pin that lets you define a current-limit level that would cause equipment
damage. If the motor torque ever exceeds the set limit, the drive will
automatically shut off the motor.
From simple across-the-line starters and soft-starters to high-performance,
speed, torque and position control linked into the Rockwell Automation
Integrated Architecture™
, you can select and connect networked intelligent
motor control products that help make data-driven diagnostic and
maintenance decisions for higher uptime. Better information leads to more
intelligently managed motors, which helps reduce energy and maintenance
costs, helps protect motor assets and helps increase operational profit.
Rockwell Automation Intelligent Motor Control Solutions www.rockwellautomation.com/solutions/intelligentcontrol
Rockwell Automation Strategic Maintenance www.rockwellautomation.com/solutions/maintenance
Rockwell Automation Integrated Architecture and Intelligent
Motor Control solutions are designed to help improve plant-wide
capabilities. Integrated Architecture bridges control and information
across enterprises by combining the Logix Control Platform with the
FactoryTalk integrated production and performance software suite.
Intelligent Motor Control helps maximize motor performance and links
networked motor control and protection devices with the functions
and capabilities of Integrated Architecture.
Across-the-Line Starting. Electronic motor protection relays allow
you to immediately access status information, motor performance
data and diagnostics.
Condition Monitoring. The Allen-Bradley Dynamix XM Series
monitoring and protection system identifies emerging mechanical
faults in critical plant assets and alerts operators to take action before
production is affected or safety is compromised.
Soft Starting. Allen-Bradley Soft Starters (SMCsTM
) minimize mechanical
wear on motor windings and equipment resulting from full-voltage
starting of AC induction motors. SMCs extend system life and increase
uptime by limiting electronic line disturbances from inrush currents
and offer multiple start and stop modes and advanced diagnostics to
improve system performance.
Variable-Speed Control. PowerFlex drives improve process performance with precise speed and torque control
to protect motor assets and save energy. An open network architecture allows information sharing across the
manufacturing enterprise.
Packaged Motor Control. In addition to saving up to 90 percent on control wiring installation time compared
to hard-wired I/O, pre-engineered, factory-tested CENTERLINE Motor Control Centers (MCCs) with IntelliCENTER
technology give you a full spectrum of operating data. IntelliCENTER software allows you to quickly and easily
configure, remotely monitor and troubleshoot motor controls.
Want to learn more? Visit www.rockwellautomation.com/go/imcarchive to watch seminars on how
Intelligent Motor Control solutions can help you optimize plant performance and protect your investment.
Maintenance Features Within Motor Control
I n t e llig e n t M o t o r C o n t r o l
Understanding the Power of Intelligent Motor Control
24 25
Intelligent Motor
Control Increases:
Motor Performance:
Accurate speed, torque and position•
control in varying applications.
Application expertise for designing motor•
control solutions.
Ease of operation and troubleshooting.•
Reliable technology.•
Protection of Motor Assets:
Variety of starting methods to help minimize•
mechanical wear.
Ability to monitor and diagnose problems,•
helping reduce downtime and costs.
Operational Excellence:
Reduced power consumption.•
Improved operational efficiency.•
“Green”manufacturing achieved as a result•
of energy-efficient solutions.
Regulatory and Safety Compliance:
Machine safety.•
Personnel safety.•
Government-regulated requirements.•
BENEFITS
The Allen-Bradley E1 Plus electronic overload relays are
the industry’s first modular self-powered devices. By using
optional side-mount accessory modules, you can cost
effectively expand functionality of the E1 Plus overload
relays and enhance machine operation and protection.

Customer Success Stories featuring Rockwell Automation Products and Services
26 27
A strategic approach
to maintenance helps
Detroit bottling
plant cut downtime,
reduce repair costs
and streamline
inventory
Rockwell Automation Services Support
Help Improve Equipment Reliability and
Cut Spare Parts Inventory in Half
Pepsi Bottling Group
In most established markets around the world, soft drinks rank first
among manufactured beverages, surpassing even milk and coffee in per
capita consumption. With product demand continuing to increase, soft
drink manufacturers have shifted to faster, more automated machinery.
However, as production lines become faster and more complex, many
plants are struggling to keep maintenance costs in check. This was
precisely the problem that managers at Pepsi Bottling Group’s Detroit
facility battled for several years.
Pepsi Bottling Group is the world’s largest manufacturer, seller and
distributor of Pepsi-Cola beverages. With annual sales of nearly $11
billion, the company’s fastest growing segment is non-carbonated
beverages, including the number one brand of bottled water in the U.S.,
Aquafina, as well as Tropicana juice drinks and Lipton Ice Tea.
As part of a 24/7 production operation, the company’s Detroit plant
ships about 27 million bottles per year.
Production at the plant begins as empty bottles are unloaded from
trucks via conveyor and transported to a depalletizer. From there,
they are, rinsed, dried and sent to a filling machine (filler speeds at
the plant vary based on bottle size, ranging from 350 to 1,000 bottles
per minute). The bottles leave the fillers and make their way to a
packaging machine, and then to a palletizer. Each pallet is wrapped for
distribution and moved to the warehouse for shipping.
Challenge
While controllers and software are the brains behind any production operation,
sensors play a critical role as the eyes and ears. The plant uses a variety of
sensors to monitor bottles as they travel through the sequence of steps and to
manage the flow to the individual stations. Line sensors match the speed of the
conveyor (controlled by variable speed drives) to the precise spacing needed for
accomplishing each production step. However, these sensors became a major issue
for the plant over the years.
Like many high volume manufacturing plants, Pepsi’s primary focus is on quality
and productivity, with less attention given to issues like parts inventory and
technology migration. As a result, the company’s inventory of sensors swelled
over the years to include more than 120 different varieties. Many of these included
multiple styles of the same product stocked under different brands. A similar
problem was developing with its drives inventory, which had grown to over 50
different part numbers.
The wide variety of sensors made it progressively more complex and
timeconsuming to replace a faulty device. Despite its fast, high-performance
machinery, the increasingly lengthy and more frequent downtime was beginning
to impact the company’s ability to meet its productivity goals. In addition,
operating costs were on the rise due to the excess spares inventory.
“Because of the extensive number of sensors we had in inventory, including
multiple styles and brands, simply finding the right replacement could result in
an hour of downtime,” said Tony Yanora, maintenance manager, Pepsi Bottling
Group. “We had a lot of specialized sensors that we didn’t really need which
increased our inventory costs and made it a nightmare for our technicians to
make repairs – if we even had the right parts in stock.”
A more strategic approach to maintenance was necessary, as even the smallest of
delays could cost the plant thousands of dollars in lost production and overtime.
Knowing that effective parts management and fast, reliable equipment repair
lies at the heart of efficient manufacturing, the company explored ways to get
its inventory and maintenance processes under tighter control. That’s when it
decided to turn to Rockwell Automation for help.
Solutions
Outsourced maintenance services to
Rockwell Automation:
Parts Management Agreement•
TechConnect Support•
HMI Conversion Services•
Standardized on:
Allen-Bradley PowerFlex Drives•
Allen-Bradley Sensors•
Results
Helped reduce parts inventory•
Reduced types of sensors used from--
180 to 46, and types of drives from
several hundred to 14
Helped reduce downtime•
Less overtime required to fill orders--
Drive failures have dropped from 1-2--
a month to just one in the last year
Virtually eliminated emergency•
parts delivery
Money spent stocking unnecessary•
inventory reallocated to other business
priorities
background
Pepsi Bottling Group worked with Rockwell Automation
to develop a more strategic maintenance approach
that helped reduce overtime and lost production.
C U S TO M ER
PROF I L E

29
“ T he P epsi B ottling G ro u p ’ s D etriot plant red u ced
its n u m b er of sensors from 18 0 to 4 6 , a decrease of
6 6 percent, by standardi z ing it sensors inventory to
A llen - B radley prod u cts . T his red u ced downtime and
inventory costs .”
28
C U S TO M ER
PROF I L E
Leveraging Rockwell Automation® Services Support has
proven to be a smart decision for Pepsi Bottling Group. The
improved inventory and parts management capabilities helped
reduce downtime and inventory costs, and standardizing
on Allen-Bradley products eased training requirements and
minimized the technology learning curve. These benefits have
helped improve productivity by eight percent and reduced
the overtime required to fill orders. In addition, the plant was
able to reduce the number of sensors it uses from 180 to 46,
a decrease of 66 percent. Likewise, it was able to reduce the
number of drive styles from several hundred to 14.
“Most importantly, unplanned downtime no longer keeps
us awake at night,” Yanora said. “With the focus on strategic
maintenance Rockwell Automation brought to us, this plant
has become one of the most efficient, productive and advanced
in the Pepsi Bottling Group.”
Additionally, Pepsi’s Rockwell Automation Services Agreement
brings in a Rockwell Automation asset management specialist
to work on-site at the plant one day a month – freeing up plant
staff to focus on core productivity issues. During scheduled
visits, the onsite consultant helps manage inventory issues,
conducts on-the-job training programs and evaluates monthly
repair reports to determine trends, analyze costs and identify
levels of spare parts usage.
In addition to the cost savings, a side benefit of the program
is the increased confidence that comes with having a remote
support group that is always available to the plant staff and can
address any plant problem, even at the most inconvenient times.
“We now have confidence that any problem we encounter can
be resolved in a timely fashion and parts will be on hand and
readily available when we need them,” Yanora said.
The improved inventory management helped the company
virtually eliminate its emergency parts delivery issues and,
because the Services Agreement has allowed the plant to
upgrade its drives, drive reliability has improved, from one
to two drive failures per month to just one in the last year.
In addition, the company can reallocate the money it spent
stocking unnecessary inventory to other business priorities.
“We’re able to reduce our inventory costs because we’re no
longer buying sensors and drives until we need them.” Yanora
said. “This has allowed us to hold the line on maintenance costs,
while still updating our equipment with the latest technology.”
Equally important, the company now has a list of the sensors
and drives it stocks and can provide this list of approved
products to its OEMs when specifying new equipment. This has
helped the plant standardize its equipment during several new
installations in the last year.
Working with Rockwell Automation has helped the company
streamline its spare parts inventory, improve equipment
reliability and move to a more strategic maintenance approach.
The combination of increased productivity and reduced
inventory costs allows Pepsi Bottling to focus on higher
priorities, such as bringing innovative product brands to
market and meeting profitability goals.
The first task undertaken by Rockwell Automation was to
conduct an Installed Base Evaluation™ – a plant-wide inventory
assessment to determine the exact number of sensors and drives
the plant currently had in stock. Next it needed to figure out
what products were actually needed and which ones could be
eliminated. To streamline its operation, Rockwell Automation
recommended that Pepsi standardize its entire sensors inventory
on Allen-Bradley products. The local distributor, McNaughton-
McKay Electric Co. (Mc Mc), helped design a migration
plan to help ease the cost of this inventory conversion.
Although all the drives employed at the plant were
Allen-Bradley brand, many were older models representing
a multitude of drive families. To help simplify its drives
inventory and upgrade its technology at the same time, Pepsi
converted all of its drives to the Allen-Bradley PowerFlex family
of AC drives. A detailed crossreference chart developed by
Rockwell Automation now provides technicians with a quicker
and easier way to identify failed and replacement parts, as well
as installation instructions.
To provide reliable availability to spare parts, Pepsi set-up a
Rockwell Automation Services Agreement that included parts
management. With the agreement, Pepsi pays a fixed monthly
cost for their spare parts, which are owned and managed by
Rockwell Automation but stocked on-site. The agreement
allows Pepsi to reduce its upfront expenses, have immediate
access to spares, reduce carrying costs, and update its control
technology cost-effectively. The agreement also includes an
in-service warranty, so the parts don’t go out of warranty until
they are actually used for the warranty period.
To help the company better utilize its internal resources and
reduce costly troubleshooting delays, the Rockwell Automation
Services Agreement included TechConnect Support. This
remote support service provides the plant with 24/7 access to
Rockwell Automation technical specialists. When a problem
occurs, Pepsi technicians can call for immediate troubleshooting
assistance to resolve it as quickly as possible. To help facilitate
problem resolution, Rockwell Automation technical specialists
can also perform remote system diagnostics through an
Allen-Bradley modem installed at the Pepsi facility.
“When you’re operating a high-speed bottling line, one thing
you definitely need is support,” Yanora said. “By allowing
Rockwell Automation to assume responsibility for our parts
management and relying on their around-the-clock support
services, we’re able to focus on productivity and uptime,
which speaks directly to the bottom line.”
As part of the Rockwell Automation Services Agreement,
and to help the plant effectively migrate its Operator Interface
systems, Pepsi utilized Operator Interface Conversion Services
from Rockwell Automation. The service included a review of
the plant’s goals, site requirements and existing HMI inventory,
followed by a detailed plan to convert the existing hardware
and software code. This helped Pepsi reduce risk and long
term costs.
solution results

Solutions
In the Semiconductor and Electronics marketplace, profits are directly affected by the
amount of time it takes to move from product design to volume manufacturing. Design
firms and system integrators like IDC must constantly focus on reducing installation and
commissioning time, developing flexible and expandable solutions, and implementing
control systems that provide data to improve operational efficiency and
ease troubleshooting.
“For our customers, time to market equals time to profit,” said Gary Mays, Instrumentation
and Controls Manager, IDC. “Our first priority is to get our customer up and running as
quickly as possible.”
Initially, IDC considered using the existing motor starters to save time, but with the help
of Rockwell Automation quickly realized a better controlled and more cost-effective
solution for the air handlers could be achieved.
Rockwell Automation and IDC have worked together to provide control systems to
Semiconductor and Electronics customers for more than 20 years. Bucking the trend of
the copy exact philosophy used in the industry, IDC and Rockwell Automation teamed
to design and implement an Intelligent Motor Control solution for the recirculation
air handlers. The solution included networked Allen-Bradley PowerFlex drives being
commanded by an Allen-Bradley ControlLogix programmable automation controller.
By networking the PowerFlex drives, IDC engineers needed to install only a single
communications cable between the drive and controller cabinets. If the engineers opted to
use the existing motor starters, they would have needed to hardwire each individual starter
back to the controller cabinet.
IDC engineers also took advantage of the PowerFlex drives I/O and wired the temperature
transmitter, control valve, damper position switches and damper solenoids directly to the
drive mounted on the RAH unit. This eliminated “homerunning” the I/O from each
RAH to a central control panel.
In addition to reducing wiring and installation costs, this approach created a centralized
point for all drive programming and file storage, providing the flexibility and integrated
capabilities that would carry the fab into the future.
30 31
C U S TO M ER
PROF I L E
Solutions
Allen-Bradley PowerFlex® 70 AC Drive-•
On-board I/O eliminates the need for
new control panels, additional I/O modules
and home-run wiring. Networking the drive
provides enhanced diagnostics.
Integrated Architecture System
Allen-Bradley ControlLogix programmable•
automation controller – Scalable,
multidisciplined controller automatically
adjusts fan speeds to keep the
cleanroom pressurized
EtherNet/IP network – Enables cost-•
effective plant-wide communication
ControlNet network – Combines the•
functionality of an I/O network and a
peer-to-peer network
FactoryTalk®View human-machine•
interface software – User-friendly displays
allow operators to monitor critical
information and to control the application
from a centralized location
Rockwell Automation Services Support
Network Services verified and validated•
the ControlNet network to ensure
proper operation
Results
The on-board I/O of the PowerFlex drives•
helped the facility save more than $500,000
in installation costs by eliminating the need
for new I/O modules and panel wiring
Reduced Operational Costs
PowerFlex drives operate at the optimal•
speed for energy efficiency
ControlNet and EtherNet/IP networks•
route critical operating data, allowing
the facility to adopt a preventive
maintenance program
The red-hot semiconductor industry cooled in the late 1990s, leading some
manufacturers to mothball new construction or expansion projects. But today, the
semiconductor industry is again thriving, fueled by advancing technology and emerging
energy alternatives. As a result, many manufacturers are reviving their inactive facilities.
When a large wafer fabrication manufacturer set its sights on updating and coordinating
the controls for the critical recirculation air handlers in the cleanroom, it called on
Industrial Design Corporation (IDC). IDC is a full service, global engineering firm that
covers all areas – design, construction and systems integration in the microelectronics
and emerging technologies industries for CH2M Hill.
Challenge
Wafer manufacturing is extremely sensitive to temperature changes, humidity levels
and contamination from airborne particles. The cleanroom utilizes extensive heating,
ventilating and air conditioning systems with highperformance filters to maintain the
cleanroom’s temperature and humidity precisely while filtering airborne particles.
High above the 125,000-square-foot cleanroom, more than 160 delivery trucksized
recirculation air handlers (RAH) are aligned in a grid. The units provide a high
velocity of air at a uniform temperature to create a unidirectional or laminar flow of air
through the cleanroom. The straight parallel streams of air at high velocity carry away
airborne particles and prevent wafer contamination. The temperature in the cleanroom
is controlled within +/- 1.5 degrees Fahrenheit. To meet this level of accuracy, each
recirculation air handler relies on a cooling coil, a set of isolation dampers, and a fan
for successful operation.
During the original fab construction, nearly 100 air handlers had been installed, but
only a few were fully commissioned before the project was put on hold. The minimum
controls that were installed only allowed for very inefficient adjustments. Since the
motors ran at a constant speed, workers had to climb several stories to adjust the air
regulator that controlled the airflow to the damper solenoids. Not only was this a poor
use of labor, but it also resulted in wasted energy and unnecessary strain on the motors.
Industrial Design
Corporation (IDC)
PowerFlex Drive:
The drive controls the fan speed to keep the
cleanroom pressurized and save energy.
Fan Deck:
The Recirculation Air Handlers are aligned in a grid
providing the cleanroom below with tightly controlled
temperature and filtered air.
Intelligent Motor
Control, Network
Services Reduce
Installation
($500,000+) and
MRO Costs at
Semiconductor
Facility
background

For our customers, time to market equals time to profit, Our first”
priority is to get our customer up and running as quickly as possible.”
Network Services
Reduce Project Costs,
Increase Network
Availability, and
Improve Productivity
Data from the factory floor is vital to
making informed business decisions
for improving key performance
indicators such as Overall Equipment
Effectiveness (OEE). Rockwell
Automation Network Services helps
you develop and maintain a fully
integrated communications network
with the speed, volume and other
functionality required of today’s
more sophisticated and complex
industrial automation and control
environments.
Network Design – By fully analyzing
and implementing your network
requirements, your network design
will fit your current and future needs
– whether fully integrated with your
business systems or completely
standalone.
Network Evaluation – Make
informed technical and business
decisions regarding upgrades/
modifications/expansions and
validate new/upgraded network
installations.
For more information visit:
www.rockwellautomation.com/
services/networks/
32 33
“When we evaluated our equipment options, Rockwell Automation did not have the lowest initial purchase price,”
said Mays. “But when we assessed the total cost to design, develop and deliver the solution, the Rockwell Automation
variable frequency drives easily paid for themselves.”
Space is at a premium inside a wafer fab, so design firms look for innovative ways to reduce equipment footprints.
By looking beyond the traditional control architecture, IDC accomplished this goal. IDC engineers designed the
RAH control system to allow field I/O to be wired directly to the drive’s I/O board; essentially using the drive as a
distributed I/O drop. Networking the PowerFlex drives I/O via ControlNet back to the controller eliminated the
space required for new panels and conduit runs, saving valuable square footage.
Drive operating status and speed is networked via ControlNet to an Allen-Bradley ControlLogix programmable
automation controller. When the RAH is in auto mode, the unit is stopped and started from the controller via the
network. The controller closes the temperature PID loop based on the actual temperature in the cleanroom and the
desired setpoint. The ControlLogix programmable automation controller automatically adjusts the motor speed as
needed to keep the cleanroom pressurized.
An EtherNet/IP connection routes critical operation information to a central control room. From there, the
FactoryTalk View human machine interface software provides operators information about each unit’s status
including fan speed, supply temperature, setpoints and control valve output percentage.
“Access to information is the foundation of Intelligent Motor Control. One of the benefits of using the PowerFlex
drives is that they provide about five times more information than a non-networked drive,” Mays said. “That gave
our customers the competitive advantage to review trending information and schedule preventative maintenance, a
critical step considering these plants often run all day, every day.”
Based on previous experience, IDC understands how critical network certification is to eliminating and preventing
communications issues. Once the ControlNet network was in place, IDC called on Rockwell Automation Services
Support to help verify and validate the network.
The results mentioned in this story are specific to Industrial Design
Corporation’s use of Rockwell Automation products in conjunction
with other products. Specific results may vary for other customers.
Customer Success Stories featuring Rockwell Automation Products and Services C U S TO M ER
PROF I L E
Rockwell Automation network engineering specialists tested the network to make
sure that the signal loss across the network was acceptable, network lengths were not
exceeded, and that all connections were made properly. Network verification helps
reduce the risk of discovering problems late-in-the-game when they are often more
difficult to identify or can have a greater impact on the overall project schedule.
“From a customer satisfaction standpoint, we understand how critical it is to get it
right the first time, but often the end user views network certification as unnecessary
or too costly” Mays said. “We believe certification should be a requirement and
included in the job specifications rather than being left up to the end user to request.”
results
The Intelligent Motor Control solution, including PowerFlex drives networked
to the ControlLogix programmable automation controller, helped IDC save the
semiconductor fab owner more than $500,000 in installation costs. Reduced wiring,
centralized configuration and maintenance has generated real savings during the
start-up and commissioning of the project. The fab owner will continue to reap
savings through better control, improved diagnostics, and easier troubleshooting.
If one of the drives needs to be replaced or a unit moved to a new location,
configuring it will take just a few minutes, compared to more than an hour
in the past.
The layout of the ControlNet network also helped IDC make certain that one
segment of recirculation air handlers did not impact the entire fab. Should one of
the drives in a zone fail, the control system will automatically adjust the speed of the
remaining drives to meet the cleanroom pressure required and prevent an impact to
production. An operator can also take manual control of any RAH unit from the
control room using the FactoryTalk View display.
“There is a potential for our customers to save considerable operational costs,”
Mays said. “The ability to change the speed of the fan motor in these units allows
the customer to select the most energy efficient motor setting for their facility.”.
Architecture:
The drive’s I/O provides a distributed I/O drop that is
networked back to the controller. The drive is mounted on the
RAH providing easy termination of the I/O devices at the unit.
Future savings will result from better control,
improved diagnostics and easier troubleshooting

Challenge
In an effort to boost its coil coating capacity and increase market share, CENTRIA
recently added a second coil coating line at its Ambridge plant and upgraded the control
technology on its existing line. With downtime costs that can run from $3,000 to $5,000
per hour or higher, maximizing uptime on both its production lines is critical and was a
key motivator for the upgrade.
CENTRIA’s primary challenge was to find a control solution that could provide a
high level of reliability and a maximum return on investment, while meeting exacting
performance and throughput requirements. The company decided to team with
Rockwell Automation for a control system upgrade that included Allen-Bradley
ControlLogix controllers to provide precise drive coordination, an integrated process
and discrete control, PowerFlex variable frequency AC drives, as well as PanelView™
operator interfaces. “Having a single control system to manage both our process and
discrete operations means our technicians only need to be familiar with one programming
and operating environment,” said Ron Mahan, Plant Engineer, CENTRIA.
As part of Rockwell Automation’s Integrated Architecture, the multi-disciplined
control system upgrade helped CENTRIA boost throughput capacity, while allowing
the company to run heavier gauge material through the coating process. With limited
personnel to assist with startup and maintenance of its coating lines, CENTRIA needed
technical support assistance that would help maximize equipment reliability and reduce
unplanned downtime.
34 35
Based in Moon Township, Pa., near Pittsburgh, CENTRIA is the nation’s premier
supplier of architectural metal wall and roofing systems used in commercial and
industrial building construction. The company provides extensive coil coating services.
CENTRIA’s coil coating facility in Ambridge, Pa. is capable of coating a wide range of
substrates, including aluminum, carbon steel, galvanized steel, stainless steel and zinc-
aluminum alloys.
CENTRIA distinguishes itself in the coil coating market with its ability to provide
custom coating services, precise color matching and rapid turnaround for both large
and small orders. The company’s in-depth knowledge of coatings, metal handling,
slitting and end-use applications enable it to meet a wide range of coil coating
requirements in industries such as automotive, transportation, residential and
commercial building and industrial products.
Though coil coating is a relatively mature market, demand for pre-painted steel
and aluminum has grown steadily among OEMs because of its low cost and
environmental advantages.
CENTRIA
Rockwell Automation
InSite™
Services
Help Company’s
Coil Coating
Operation Reduce
Downtime and
Maximize Equipment
Reliability
background
C U S TO M ER
PROF I L E
With downtime costs that can run from $3,000
to $5,000 per hour or higher, maximizing uptime
on both its production lines is critical

The return on investment from the InSite service”
has been quick and substantial, so obviously, we’ve been
very pleased with the results we’ve gained from the service.”
36 37
Solutions
To meet uptime and throughput goals while helping minimize maintenance costs, Rockwell Automation
recommended its InSite services. This comprehensive support service has provided CENTRIA with around-
the-clock direct access to a designated team of support specialists who have an intimate knowledge of the
company’s coil coating process and all control system components. The InSite service has proven instrumental
in helping CENTRIA improve equipment performance, increase operation consistency, and troubleshoot and
solve problems more quickly. An added bonus for CENTRIA was the ability of Rockwell Automation to offer
this service as part of a bundled contract with the control system upgrade.
Another facet of this service that has helped CENTRIA establish a predictive maintenance strategy,
preventing problems before they occurred, is the remote monitoring and diagnostics capabilities. This allows
off-site Rockwell Automation engineers to continuously monitor the control system on CENTRIA’s coating
lines (via a secure high-speed broadband connection), proactively watching for signs of trouble that might lead
to unplanned downtime.
With InSite assistance, engineers at the Rockwell Automation Command Center continuously assess
production status using proprietary software applications to compare real-time and historical process data
to a predetermined optimal range. If a parameter deviates outside the range, the InSite staff will notify
production personnel at CENTRIA – often before the company realizes there is a problem – and then begin
troubleshooting activities to diagnose the cause and determine corrective actions. Once Rockwell Automation
engineers determine corrective measures, they collaborate with the plant maintenance staff to execute the
actions and restore normal operations.
Customer Success Stories featuring Rockwell Automation Products and Services C U S TO M ER
PROF I L E
Results
The InSite service has proven extremely effective in helping CENTRIA resolve
problems before a downtime situation occurs, while at the same time helping
to boost equipment reliability, increase throughput and improve product quality.
“We knew we needed a solution that could not only reduce the length of downtime,
but prevent it from occurring in the first place,” said Ron Mahan. “The return on
investment from the InSite service has been quick and substantial, so obviously, we’ve
been very pleased with the results we’ve gained from the service.”
Rockwell Automation off-site engineers can use the remote monitoring technology
to tune drives and remediate quality issues. A continuous log of operating history
is recorded to help identify trends and simplify troubleshooting. Since start-up,
CENTRIA has needed a service technician on-site only twice. Before the update,
breakdowns occurred several times per week.
In its first year of operation, the InSite service has helped CENTRIA boost its coating
productivity and help significantly reduce its downtime and scrap costs.
In one instance, CENTRIA ran into an embossing problem which was causing the
metal to tear. The InSite staff identified the problem right away and quickly initiated
the appropriate corrective action. Without the monitoring service in place, it would
have taken operators hours to even realize there was a problem, resulting in substantial
product losses.
“The InSite service is critical in helping us avoid equipment and product damage,” said
Ron Mahan. “The support we get from the InSite staff is phenomenal. It’s like having
someone continuously standing over your shoulder, constantly pointing out potential
problems and then letting you know how to correct them.”
Using Rockwell Automation as a single-source provider for advanced control
technology, engineering and application experience, and complete system support,
CENTRIA has realized newfound efficiency and reliability for its continued
growth. The combination of expanded capacity and improved uptime have allowed
the company to focus on higher priorities, such as meeting customer needs and
improving profitability.
The combination of expanded capacity and improved uptime
have allowed the company to focus on higher priorities,
such as meeting customer needs and improving profitability.
InSite SERVICES
Leaner staffs and reduced budgets can
make it a challenge to install, operate and
maintain the automated processes you
need to remain competitive and meet
market demand. Rockwell Automation
InSite Services, our premium Remote
Support Service, will help you meet the
challenge.
Whether trying to improve staff utilization,
line/plant operational performance, or
plant profitability – or you simply want
the fastest and most comprehensive
technical assistance – InSite Services
will help you reduce costs and achieve
operational excellence.
Available across the globe and around
the clock, InSite Services will help you
meet your objectives through five
separate service components that can be
combined for and tailored to your system
and application.
Surveillance (proactive 24x7x365•
system monitoring)
Diagnostics (24x7x365 technical•
support from a designated team)
Administration (control/process/•
manufacturing application management)
Optimization (system/application•
enhancements)
Knowledge (management of information•
specific to your system/application)
Visualization (online portal for your•
plant floor data)
For more information on how InSite
Services will help your company,
see pages 76-77.For more information on InSite visit:
www.rockwellautomation.com/services/remote

1784-CF64
Industrial CompactFlash™
64MB Capability
POWER
ETHERNET Logix5550
AB
Control
A # 2 4
DC INPUTDC OUTPUT AC INPUT AC OUTPUTDH+/RIO
B#15
ANALOG OUTPUTANALOG INPUT
0.00
2.5
646.0
Hz
Cans/Sec
Bus/Volt
PORT
MOD
NET A
NET B
STS
Firmware
Kits
T
I
P
S
E C H
T
I
P
S
E C H
38 39
ROCKWELL AUTOMATION
SUPPORT SPECIALISTS TELL
YOU HOW TO MAINTAIN YOUR
AUTOMATION
EQUIPMENT TO OPTIMIZE
PERFORMANCE AND UPTIME
Using Logix 5000 Firmware Supervisor
in RSLogix™
5000 version 16
Increase productivity while streamlining controller setup,
installation and maintenance with Rockwell Software®
RSLogix 5000, version 16.
The latest version of Rockwell Software RSLogix 5000 software
from Rockwell Automation includes more than 30 product
improvements that help users simplify programming and
configuration and ease maintenance and troubleshooting of
control and inform ation systems.
Key features in RSLogix 5000 v.16 include user-defined Add-On
Instructions (AOI) — designed to improve standardization and
code reuse; and integrated drives configuration — one of the first
of its kind in the industry, potentially resulting in faster setup,
improved accuracy and easier maintenance of drive systems.
With the increasing complexity of production lines and machines,
the ability to consolidate control disciplines into a single, integrated
environment offers considerable time and cost-saving advantages.
Version 16 allows the Rockwell Automation Logix Control
Platform to dig deeper into process control applications, while
the integrated drives configuration and Kinematics robot control
functions further collapse drives and motion control system
programming and configuration into a single software package.
Starting with version 16, controllers can flash update
modules configured in the I/O tree on mismatch
situations without user intervention. The following
provisions apply to this feature:
Local and remote modules can be flashed while•
in Program and Run modes
Modules must have Electronic key parameter•
set as “Exact Match” and support ControlFlash™
Firmware kits reside in the controller’s•
CompactFlash card
Feature enabling and transfer of firmware kits to•
CompactFlash card is configured and initiated during
a Store to Nonvolatile memory operation (need to
be online and in Remote Program mode)
Feature can be controlled programmatically via•
GSV/SSV instructions
PowerFlex® 70 and 700 drives are supported•
Peripheral modules will be supported at a later time•
GuardLogix will support this feature at a later release•
PowerFlex 70 and 700 drives currently support the
flash update feature. Peripheral modules and GuardLogix®
controllers will support this feature in the future.
T
I
P
S
E C H
the order of troubleshooting steps is important. Start with Step 1 and work your
way down. Skip any steps that you know are not necessary.
Enabling the Flash Update Feature
Set 1756-ENBT/A module to revision 3.9
and 1756-CNBR/D module to revision
5.50, Electronic Keying must be set to
Exact Match.
The following example shows steps necessary to enable the flash update feature.
1
2 In Controller Properties, select the
Nonvolatile tab and verify the Inhibit
Automatic Firmware Update box is
not checked.

40 41
T
I
P
S
E C H
3
4 In Controller Properties select Load/Store
from Nonvolatile Memory tab.
Select Enable and Store Files to Image
and click Store button.
Firmware Supervisor software will save
firmware files to the Compact Flash card first,
and will save Application after that.
Control Flash Firmware files for all required
modules must be installed on this computer.
If Firmware Supervisor software can’t find the
firmware file, the following warning
will be shown.
After CF store operation is complete, the
controller will immediately start the firmware
update for modules selected.
No user prompt will be issued even if Load
Image is set to User Initiated.
Download project to the controller, leave
controller in Program Mode after download.
Because no firmware is on the Compact
Flash card yet, you will see an error in
I/O configuration.
5
6
Connect to the controller online again.
I/O configuration warnings will indicate
Firmware update in progress.
Modules will go to the Run mode as soon
as the firmware update completed.
Automatic Firmware Update status can be
monitored and changed programmatically
from the application using GSV/SSV
instructions.
TECHCONNECT SUPPORT
OBTAIN UNLIMITED SUPPORT FOR
YOUR AUTOMATION ISSUES
Need help with the firmware
update feature in RSLogix 5000?
With TechConnect Support, you will
get the answers you need to resolve
your issues quickly and accurately.
To best help meet your needs, TechConnect
provides unlimited access to Rockwell
Automation support specialists via three
service levels:
eConnect – e-mail support for1.
non-critical issues/applications.
DirectConnect2. SM
– unlimited, real-time
phone support*. Also includes
e-mail support.
PriorityConnect Systems Support –3.
unlimited, real-time phone support*
by senior engineers for system issues
and process applications. Also includes
e-mail support.
Standard coverage 8 am - 5 pm local time.*
24/7 coverage optional.
For more information visit:
www.rockwellautomation.com/services/
remote/techconnect/Need help with a technical issue? Go to Get Support Now at
www.rockwellautomation.com/support for support tools,
resources and services.

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