StrategicMaintenance7-28-07

strategic
maintenance
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FEATURES
4 What’s New in Maintenance
14 Feature Article
Measuring the Success of your
Maintenance Strategy
22 Industry Solutions
Maintenance in the Brewing Industry
24 Customer Results
Controlling the Compressor: Air Liquide
32 Tech Tips
Rockwell Automation Support Specialists
Help You Optimize the Performance of
Your Automation Assets
38 Q&A
Answers to Common Maintenance-related Issues
50 eTools
56 Products, Services & Support
88 What’s Next in Maintenance
New Rockwell Automation Products, Product
Enhancements and Services related to
Maintenance that will be available soon
91 Contacting Rockwell Automation®
Services & Support
24
theSuccessof your
Sucu
Maintenance Strate
y
Measuring
FEATURE ARTICLE
22
Kevin Oswald (
kjoswald@ra.ro
Contributing edi
Laurie Rehberga
Lori Knapper, St
Georgene Berma
Jan Zuehlke, Ka
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strategic
maintenance
PRODUCTS,
SERVICES &
SUPPORT
58 ASSESSMENT SERVICES
60 CONDITION MONITORING
• Condition Monitoring Systems
• Emonitor®
Software
• Condition Monitoring Services
68 ASSET MANAGEMENT
• Asset Management Services
• RSMACC™
Software
72 SUPPORT
• Remote Support Services
• OnSite Support Services
76 NETWORKS & COMMUNICATIONS
• Network & Security Services
• Remote Access Dial-in Modems
80 TRAINING SERVICES
86 REPAIR SERVICES & RENEWAL PARTS
NOTE: Service availability/features may vary by country or region.
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WHAT’S
IN MAINTENANCE
NEW
4
www.rockwellautomation.com/services/rmd/enetmodule
ETHERNET DIAGNOSTIC MODULE
Maximize your network uptime and overall productivity by monitoring network status
through the control system. With the Allen-Bradley®
Ethernet Diagnostic Module
(9300-8EDM), you now have real-time access to critical network data through your
Logix-based control system. The Ethernet Diagnostic Module appears as standard
I/O, seamlessly integrating into Logix programs and updating tags automatically.
This allows you to continuously monitor your network for configuration changes,
traffic overload, and unauthorized access – and proactively implement changes
to prevent a significant reduction in performance or unplanned downtime event.
www.rockwellautomation.com/services/conditionmonitoring/protection.html
XM®
160 SERIES OVERALL VIBRATION MODULES
XM®
is Allen-Bradley’s
award winning family
of distributed machine
condition monitoring
and protection devices.
With the comprehensive
XM family, discreet or networked
monitoring solutions can be quickly and cost
effectively deployed for steam, gas/hydro turbines,
motors, compressors, pumps, fans, blowers and most
other rotating machinery.
The XM 160 Series of Overall Vibration Modules
are intelligent 6-channel monitors designed to cost
effectively serve applications for real time monitoring
of overall (direct) vibration levels. Designed as a
simple but complete monitoring system in a compact,
easily installed, easily maintained package, each
module measures and reports the overall vibration
level between selected high and low pass filters, as
well as the bias (gap) voltage per channel.
The XM 160 Series includes three modules:
XM-160 Overall Vibration Module offers
an economical solution for monitoring of
accelerometers and self or externally powered
sensors. Via DeviceNet™
, the module can be easily
integrated with other XM modules, PLC controllers,
DCS systems, graphical displays (HMI) and condition
monitoring systems. For standalone applications, the
XM-160 includes comprehensive alarm logic per
channel and supports linking of up to two XM-441
Expansion Relay modules thereby providing a total
capacity of up to 8 relays.
the same capabilities as the standard XM-160 but
also includes a 4-20mA output for each channel.
the same capabilities as the standard XM-160
but incorporates a DC power supply suitable for
powering standard -24V eddy current (proximity)
probe drivers.
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WHAT’S NEWIN MAINTENANCE
55
www.rockwellautomation.com/solutions/intelligentcontrol
INTELLIGENT MOTOR CONTROL SOLUTIONS
Reduce your maintenance costs and downtime with our comprehensive
portfolio of Intelligent Motor Control products. As part of a truly Integrated
Architecture, these products can help you:
• simplify your start-up
• reduce your installed cost
• make it easier for you to access essential plant and production data
With the following enhancements, you can now realize greater
maintenance related benefits from our Intelligent Motor Control products:
Across-the-line Starting
with E1 Plus Electronic Overload Relays
The new E1 Plus offers a self-powered design, responsive phase loss detection, wide
5:1 adjustment range, and DIP switch selectable trip class for flexible application.
The optional, side-mounting DeviceNet™
module offers two discreet inputs and an
output relay for motor starter related I/O. Protection enhancing functions include:
overload warning, jam trip and warning, and underload warning.
Pre-Packaged Motor Control
with IntelliCENTER®
RR Motor Control Centers
IntelliCENTER®
Software Version 2 further enhances
your intelligent motor control experience with easy
online configuration, electronic documentation and
pre-configured screens for monitoring devices. Using
IntelliCENTER software, a typical maintenance
electrician can quickly learn to configure, monitor
and troubleshoot electronic motor controls without
first becoming a network expert.
Variable Speed Control
with PowerFlex®
x AC Drives
Regenerative Liquid-Cooled PowerFlex drives utilize integrated active converter
technology and also offer improved power quality over a wide range of industrial
power voltages. Easy to use features include:
• Simplified programming with full-featured LCD Human Interface Module (HIM),
multi-line and multi-lingual display
• Effortless configuring and tuning of the drive with S.M.A.R.T™
start and
detailed assisted start-up routines in the LCD HIM
• Straight forward programming, configuration, monitoring and troubleshooting
are easier with PC software tools, such as DriveExplorer™
, DriveTools™
SP
and RSLogix™
5000
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6
www.rockwellautomation.com/rockwellsoftware/assetmgmt/rsmacc/index.html
Rockwell Software Maintenance Automation Control Center (RSMACC) Change
Management software has added Verification functionality for Rockwell Automation
drives through the Verification add-on. The Verification add-on provides back-up
of Rockwell Automation drives configurations and a comparison of the current
Rockwell Automation drive configuration to the master configuration.
To use the Verification add-on, the drives must be on a network. Supported
networks include DeviceNet™
, ControlNet™
, Ethernet/IP™
, and Data Highway Plus™
(1336T Force and 1395 only).
RSMACC software offers an integrated, modular approach that lets you
proactively and centrally manage your automated production environment by:
• Securing access to the control system
• Tracking users’ actions
• Managing asset configuration files
• Providing backup and recovery of operating asset configuration files
(disaster recovery)
By providing a single point of access for gathering, analyzing, and managing control
system information across your enterprise, RSMACC gives you intimate knowledge to
make better maintenance and operational decisions.
RSMACC™
CHANGE MANAGEMENT SOFTWARE
ADDS VERIFICATION FUNCTIONALITY FOR
ROCKWELL AUTOMATION DRIVES
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7
www.rockwellautomation.com/rockwellsoftware/news/
Rockwell Automation recently acquired GEPA mbH, a leading European provider
of change management software for industrial automation, process control and
industrial information technology. The acquisition of GEPA complements the
company’s strategy for expanding the asset management offerings within its
FactoryTalk®
integrated production and performance suite.
Headquartered in Landau, Germany, GEPA has been providing its VersionWorks®
for Automation software application to a primarily European customer base
for nearly a decade. A modular change management software program,
VersionWorks helps manufacturers schedule automatic program backups from
controllers and other industrial devices, document change processes required
for regulatory compliance, and recover data quickly and more cost-effectively
following a disaster.
In late 2005, Rockwell Automation announced plans to create an integrated
suite of plant-wide information software - Rockwell Software FactoryTalk - through
both development and acquisition. GEPA VersionWorks complements Rockwell
Software RSMACC™
change management software, and includes change
management and version control functionality for Siemens, Beckhoff, Schneider,
Wonderware, Citect, ABB, Fanuc and Kuka robotics, among others. In future
releases, VersionWorks and RSMACC will merge into a single product called
FactoryTalk AssetCentre as part of the FactoryTalk suite.
By leveraging GEPA’s intimate third-party knowledge base, Rockwell Automation
will begin to extend its connectivity to third-party devices throughout the
FactoryTalk suite resulting in better plant asset utilization.
ROCKWELL AUTOMATION ACQUIRES
CHANGE MANAGEMENT SOFTWARE COMPANY
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www.rockwellautomation.com/services/training/workstations.html
88
www.rockwellautomation.com/rockwellsoftware/assetmgmt/security/index.html
Today’s manufacturing environment demands that you be
flexible and quick to act. The demands are high, but at
what cost to your plant security?
FactoryTalk®
Security Software provides centralized
authentication and access control by verifying the identity
of each user who attempts to access the automation
system, and then by either granting or denying each user’s
request to perform actions on resources within the system.
A “securable resource” is any object in an automation
system to which a security setting can be applied, such
as the automation system itself, applications, areas within
applications, networks and devices, and system-wide
policies. Each resource is associated with a set of actions
that can be performed on it, such as “read,” “write,”
“go online,” “delete,” and so on.
For each resource, a security setting identifies which users
(or groups of users) are granted or denied permission to
perform particular actions on this resource from specific
computers (or groups of computers).
FACTORYTALK®
KK SECURITY SOFTWARE*
INTEGRATED ARCHITECTURE WORKSTATION
Providing hands-on experience for training or pre-deployment testing allows you to
simulate real-life plant issues in a no risk environment. Built from the same proven
Rockwell Automation technologies you use every day, our Integrated Architecture
workstation will help you develop and build a solid foundation of Integrated
Architecture and automation system knowledge. The Integrated Architecture workstation
will allow you to establish communications, program a basic RSLogix™
5000 project
and configure drives, motion, and visualization applications. NetLinx-enabled networks,
DeviceNet™
, ControlNet™
, and EtherNet/IP™
will be included for distributed control.
* formerly RSAssetSecurity™
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www.rockwellautomation.com/services/repair/
www.rockwellautomation.com/services/phone/
9
REPAIRTRAK
SM
PROGRAM
RepairTrakSM
is a unique repair program which provides the
tools to improve the reliability and availability of your electronic
manufacturing equipment - starting with the right spare parts when
you need them!
The foundation of RepairTrak is Rockwell Automation’s
comprehensive Remanufacturing Service. But RepairTrak is much
more. It also includes a 3-Year Warranty on remanufactured
equipment and a variety of tools to help you better understand
your equipment usage, what caused it to fail and even locate the
status of your repair(s) currently in the remanufacturing loop. Your
local distributor will pick up your failed or malfunctioning items
through our BoardRunner™
service to begin the repair process.
Expanded access to our online repair
management Web site
• Access plant specific reports
• Determine repair status in the
remanufacturing loop
• Track shipments back to
your facility
• Request/access remanufacturing
& repair prices
World class remanufacturing services
• Original component replacement
• Product updates/revisions/
engineering change records
• Testing to Rockwell Automation
design specifications
Plant specific pareto analysis &
probable cause & warranty reports
• Better understand plant
usage patterns
• Uncover corrective
engineering opportunities
• Understand reasons for circuit
board failures
• Review parts replaced in
the manufacturing process
ENTERPRISE TECHCONNECT
SM
SUPPORT
Enterprise TechConnectSM
provides the features of TechConnect Support in a single
agreement covering all of your sites. Benefits of the single agreement include:
• Simple contract administration – one agreement to purchase, one universal
authorization number, and one expiration date for easy renewal
• Consistent support coverage across all sites
• Universal access to the most current software updates for all sites
• Support activity reports to help manage your operations, software
licensing and training requirements
• Multi-year pricing options
Complete RepairTrak features include:
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10
www.rockwellautomation.com/services/training/rstlx5kmot.html
RSLOGIX™
5000 MOTION SELF-PACED TRAINING COURSE
This interactive, self-paced training course teaches the core tasks required
to effectively program motion control applications. The course is available
in both computer-based and web-based delivery formats and is part of a
series of self-paced training courses on using RSLogix™
5000 software.
In this course, you will learn how to configure servo modules, program
motion instructions, and test and tune axes through step-by-step
demonstrations. Through the demonstrations, you will learn about the various settings and options
in the software and see how to perform the required tasks for motion applications.
The course includes a variety of knowledge and learning tools including animations, background
information, interactive simulations and links to other reference materials. These tools, combined with
the step-by-step demonstrations, provide the knowledge and skills required to perform each task.
You have the opportunity to practice software tasks through interactive simulations. The simulations guide
you through the required steps and give immediate feedback on your performance to reinforce learning.
www.rockwellautomation.com/services/training/workstations.html
ETHERNET/IP™
TRAINING WORKSTATION
This self contained EtherNet/IP™
network allows you to control analog and
digital I/O from a variety of platforms while monitoring the health of the
network using EtherNet/IP modules’ built-in web-enabled technologies. The
workstation can be used to extend your network design and configuration
skills, enhance your network troubleshooting skills, and reinforce other
network skills developed during a training class. It is a hands-on resource to get you up-to-speed on
EtherNet/IP technology or maintain on-the-job skills in a no risk environment. You can develop and
test new projects in advance of actual implementation, helping you get the most benefit from your
investments in technology and employees.
This workstation can be used in conjunction with the following products:
• EtherNet/IP Network Procedures Guide
• EtherNet/IP Networks Documentation Reference Guide CD-ROM
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11
www.rockwellautomation.com/services/training/schedules.html
INTRODUCTION TO AUTOMATION AND INTEGRATED
ARCHITECTURE INSTRUCTOR-LED TRAINING COURSE
This two-day, introductory course develops and builds a solid
foundation in Integrated Architecture and automation system
knowledge. It will give you a broad understanding of automation
products and serves as an excellent first step when beginning any
automation training.
Your classroom experience includes hands-on instruction using a
variety of automation equipment including Rockwell Automation
software to perform basic system configuration tasks. While
performing these tasks, you will gain an understanding of how
controllers, drives, motors, networks, and HMI products function
together within Integrated Architecture.
Course Agenda:
• Identifying Components of
Integrated Architecture
• Establishing Communications
in an Integrated System
• Identifying Programming Languages
in an Integrated System
• Programming a Basic RSLogix™
5000
Project for an Integrated System
• Programming with Tag-Based
Addressing in an Integrated System
• Understanding Logix5000™
Multi-Discipline Control
• Understanding NetLinx-Enabled Networks
• Understanding the Visualization
Development Environment of an
Integrated System
• Understanding HMI Direct Tag
Referencing in an Integrated System
To view course dates and locations, go to: www.rockwellautomation.com/services/training/schedules.html
TRAINING VOUCHERS
Do you have diverse employee development needs but a limited training budget?
Our Training Voucher Account maximizes your training budget by allowing you to
prepurchase vouchers for Rockwell Automation training courses and products at
a discounted cost (up to 20%). You can redeem the vouchers at the time that best
meets the individual needs and schedule of each employee.
The vouchers can be redeemed at any time within one year for instructor-led
courses, self-paced training, job aids, and workstations. A convenient online
account management tool and monthly statement help you track your
voucher usage.
www.rockwellautomation.com/services/training/savingsprogram.html

12
www.rockwellautomation.com/services/onsite/conversion.html
HMI CONVERSION SERVICES
With HMI Conversion Services from Rockwell Automation, you can
leverage our automation expertise to help you successfully migrate
from PanelView™
to PanelView™
Plus operator terminals. With these
services, you can realize the following benefits:
• Improved process availability and production capacity
• Improved manufacturing quality
• Decreased long term costs and unplanned downtime
HMI Conversion Services begin with a review of your organization’s
goals, objectives, specific site requirements, existing HMI inventory and
hardware and software programming. A service scope of supply for
the project will be developed, and a fixed price proposal is submitted
for your approval.
Upon acceptance, Rockwell Automation will be with you every step of
the way throughout the conversion project – from project leadership to
start-up and acceptance.
Project Leadership
A Rockwell Automation project leader will be assigned to be your
primary contact and coordinate/schedule all project activities.
On-site Assessment
Using standardized checklists and processes, our primary engineer
will confirm project scope, validate project risks, review testing and
acceptance criteria, and gather the required information and software
to convert existing screens and software code.
Conversion Engineering
Utilizing applications designed to convert existing screens and code,
our engineers will complete and test the screen conversion process
and any required PLC code changes necessary for a like conversion.
Start-up and Acceptance
Prior to site installation, all software will be loaded on the new
terminals and a functional test will be performed. Following installation,
our engineer will work closely with you to perform an operational test
for each machine. This test will validate the conversion and ensure
operational compliance. Complete documentation will be provided
upon acceptance of the project.
>>>

www.rockwellautomation.com/services/rmd
13
www.rockwellautomation.com/services/
ONLINE MAINTENANCE
REPORTING AND ANALYSIS
Turning condition monitoring data into actionable predictive
maintenance is key to a successful Condition-based Maintenance
(CbM) program. However, collecting and analyzing data can
often be a difficult and time-consuming task.
With the new online maintenance reporting and analysis tool
from Rockwell Automation, you can easily sort, filter and summarize condition monitoring
data to maximize the benefits from your CbM program. Functions include:
• Sort at the corporation, regional, business or plant level
• Filter by collection dates, equipment, equipment type, problem severity or current
maintenance status
• Report/trend potential problems and view recommended/executed corrective action for each
• Edit program data to ensure the reported information has maximum benefit within
the specific maintenance process
• Calculate cost savings of proactive maintenance versus run to failure methods to help
determine the return on your CbM program investment
The online maintenance reporting and analysis tool is also flexible, working as an automated
gateway with existing Computerized Maintenance Management Systems.
TEAMSUPPORT™ 360 SERVICES
TeamSupport™
360 Services provide continuous remote
monitoring and 24x7 proactive technical support to help
you improve Overall Equipment Effectiveness and optimize
human performance. TeamSupport 360 helps provide a
competitive advantage to manufactures by:
• Reducing scheduled and unscheduled downtime
• Improving machine performance
• Reducing startup and changeover times
• Driving operational consistency
• Guiding operators and technicians through troubleshooting
• Providing accurate, real-time performance data to make
informed business and automation decisions
At the heart of every TeamSupport 360 program is a core team of experienced Rockwell Automation engineers that have
reviewed your specific application(s) and have your most recent system documentation on hand. Our engineers will act as
an extension of your maintenance and engineering organization by providing real-time monitoring and analysis of your
production data via a secure, high-speed web-enabled connection to your automation network(s). Combining engineering
experience with software-based diagnostic tools, our team will proactively respond to critical alarms and will immediately
contact your plant personnel to suggest corrective actions. With TeamSupport 360, in the unlikely event an issue cannot
be resolved remotely, Rockwell Automation will dispatch a local field service engineer to your facility at our expense.

Measuring
theSuccess
of your Maintenance Strategy
By Scott Teerlinck
Director, Commercial Marketing
Customer Support & Maintenance
Rockwell Automation
For many companies, manufacturing and production equipment often represent their single largest capital
investment. Furthermore, the maintenance of these assets can significantly impact the top and bottom line.
However, despite the financial impact of maintenance, many organizations have not established a consistent
method to measure the value of their maintenance activities. Often this results in underestimating the impact
maintenance can have on the financial performance of the firm.
Developing a methodology for measuring your production processes provides guidance for needed maintenance
activities and shows a continual impact on return on investment (ROI). After you establish metrics for maintenance
activities, you can also justify the value of current activities and support the case for new initiatives. This is especially
true when initiating a major change to your maintenance strategy, such as moving from a reactive approach to
a proactive approach to maintenance. Without tangible evidence in the form of objective performance data,
obtaining full support from management to make the change is more difficult to achieve.
F E A T U R E A R T I C L E
14
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T
ancehe cornerstone for any successful maintena
strategy begins with clearly defining and
ness).communicating goals (production and busi
mance,Without clearly defining the desired perfor
neratealong with the reasons for it, companies often gen
vital toa long list of metrics, yet overlook many that are v
making critical performance-enhancing decisions.
forWhile most companies collect performance data
e informationproduction assets, the challenge is to focus on the
that is most relevant. Managing with the right metrics allowthat is most relevant. Managing with the right me
companies to thoroughly understand the effect maintenance
efforts can have on overall financial performance.
Today, companies are turning to a variety of financial metrics,Today, companies are turning to a variety of fina
commonlysuch as Return On Net Assets (RONA). RONA is
a companyused by plant management to calculate how well
aintenanceleverages production assets to generate profit. Ma
on for RONA:ies impact all three variables of the equatio
.us Costs divided by Net Assets.
ccess ofmeasure the suc
ctivenessa maintenance strategy is Overall Equipment Effec
w efficiently(OEE). OEE is a statistical metric to determine how
ulateda production line or machine is running. It is calcu
ity andby multiplying a machine’s production Rate, Qual
hreeAvailability. In other words, the product of these th
towardratios is the relative value a machine contributes to
full production.full production
All companies have data and information but many do not
properly collect or analyze it to make informed decisions.
Proper analysis of the right metrics can help reduce spare
parts inventory, boost availability and maximize uptime of
production assets. Although maintenance has been proven
to impact all of the above, it is most commonly focused on
reducing downtime.
A leading semiconductor manufacturer’s
decision to migrate toward a more
predictive maintenance strategy was
directly tied to its business goals. In an
industry where a few hours of downtime can result in millions
of dollars in losses, success is measured by uptime.
In semiconductor manufacturing, every part of the facility
plays a critical role in the process. If any part of the facility
fails, such as the plant power grid, HVAC or water treatment
system, production could come to a rapid - and costly
- standstill. Using advanced condition monitoring technology,
the company designed and implemented a comprehensive
predictive maintenance program that allows it to effectively
monitor, analyze and track equipment performance -
observing operating conditions locally as well as remotely,
across multiple production sites.
The reality is
that replacing a
fan or pump motor is
a fraction of the cost of having a fabrication line down for
any amount of time. If production is down for even one or
two hours, the lost revenue would far exceed the cost of a
replacement motor, or any other ancillary component.
Since implementing the predictive maintenance program,
the company has found countless minor vibration issues and
identified several hundred major vibration problems, which
were corrected before a prolonged production shutdown
occurred. More importantly, it has realized a five-to-one return
on investment (ROI) for the condition monitoring equipment,
and the program helped the company avoid estimated lost-
production costs of more than $1.4 million in a single year.
A complete review of
maintenance operations and
the physical asset management
process can help identify
equipment and operator performance issues and outline
recommended corrective actions that can be implemented
through maintenance initiatives. For example, in critical
applications, companies may want to have redundant or
backup equipment in place to avoid production interruptions
in the event the primary piece of equipment fails or needs
to be shutdown.
This type of in-depth evaluation is important because it
gives a baseline for making improvements and validating
results. It also can help determine which maintenance
activities will have the most impact on the company’s core
business objectives and can assist in identifying key areas of
improvement, including if a different approach (predictive vs.
reactive) will be more effective.
Once you’ve identified the most critical elements impacting
production performance, you can begin to make a physical
linkage between the maintenance approach for production
assets and improved results.
Determining What to Measure
Revenue
Expenses
Assets

A STRATEGIC APPROACH TO MAINTENANCE
Characteristics of a PREDICTIVE
MAINTENANCE Approach
• Maintenance actions performed
when a need is identified
• Use comparative date to assess
the probability of future events
and performance
Apply a predictive approach:
• When downtime avoidance is critical
• If product quality is affected
• When repair and replacement
costs are high
PREDICT
16
To meet today’s more demanding production and business
goals, you can no longer take an a la carte approach to
maintaining production assets. Instead, it is now necessary
for you to use a strategic approach to maintenance.
Strategic maintenance includes a comprehensive plan
that identifies maintenance-related issues across every
organizational function within your company and then
specifies and implements the system architecture and
predictive, preventive and reactive maintenance methods
to meet your needs and objectives. By implementing the
right architecture and maintenance methods, you can
obtain the following benefits:
Characteristics of a REACTIVE MAINTENANCE Approach
• “Run till it breaks”
• No routine tasks are performed
• Equipment is repaired/replaced only when obvious problems occur
Apply a reactive approach:
• When length and frequency of downtime is not critical
• When product quality is unaffected by downtime events
• If repair or replacement costs are not an issue
REACT
Characteristics of a PREVENTIVE
MAINTENANCE Approach
• A time-based approach where
actions are performed on a
predetermined, periodic basis
• Anticipates and prepares for
planned downtime
Apply a preventive approach:
• When failure mode is well established
• When warranty terms require it
• When cost of repair or replacement
is relatively small
PREVENT
Return on Net Assets (RONA) and Overall Equipment Effectiveness (OEE)
are often used to measure the success of a maintenance strategy.
To assure objectives are met, the proper internal and external
resources are identified to execute the specified maintenance
activities, and the effects of the activities are continuously
measured. While many key performance indicators can be
measured, improvement in just two – Overall Equipment
Effectiveness (OEE) and Return on Net Assets (RONA)
– can validate your maintenance strategy.
Overall Equipment Effectiveness (OEE)
% Availability x
% Quality x
% Rate =
= Return on Net Assests (RONA)
Net Assest
Plant Revenue -
Costs
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Any established metrics should focus on the level of improvement required to
move from the current level of performance to the desired level. Defining this
difference enables companies to better determine the specific maintenance
actions, strategies and initiatives they need to undertake. To establish a
successful measurement system, managers need to know:
• The desired level of performance in quantifiable terms
• How the current performance levels are to be determined
• Specific actions that can be taken to close the gap
between the current level and desired level.
Performance measures should reflect how the maintenance department is
providing value. For instance, in the power generation industry, the expense
of downtime is calculated in cost-avoidance terms based on the profit from
generating a megawatt-hour of electricity. Depending on the plant, the profit
for a megawatt-hour varies drastically - ranging from $5 to $25 per hour.
At one 56MW power plant in California, the cost-avoidance is calculated
at $21 per megawatt hour. Therefore, downtime at this plant could cost
upwards of $11,000 an hour (or $265,000 a day).
By measuring the value of the downtime for a production department or unit, you
can often quickly determine how and where to place your maintenance efforts.
This enables you to more accurately focus your maintenance plan on the areas
that will have the most financial impact when downtime occurs. You can then
record the cost of failures while focusing efforts directly to those causes.
In some cases, depending on the size of the plant, the type and volume of
data needed to formulate the necessary metrics are not always available.
In these instances, implementing the data collection or measurement technology
can be an investment in itself. For example, you may need a software package
to collect information to help measure production rates, equipment availability
or the amount of scrap coming off the line. With the data collected, you can
then begin to build your metrics off that data.
In an industry where margins are low and parts are needed on a 24/7
basis, the correlation between equipment uptime and profitability
is abundantly clear for the semiconductor supplier referenced
earlier. To maximize equipment reliability, the company established
a comprehensive spare parts management program that has
helped it improve parts availability, increase manufacturing efficiency, reduce
downtime and minimize its spare parts inventory investment.
The parts program has been instrumental in helping the company meet its
aggressive production goals while minimizing costly downtime. Since putting
the program in place, the company has reduced its spare parts
inventory by 25%, helping save approximately $250,000
in inventory expenses. Moreover, it credits the parts program for helping the
facility boost its capacity by 250% - which helps the company significantly
increase its return on net assets.
MeasuringSuccess

As previously mentioned, developing a methodology for
measuring your processes provides guidance for needed
maintenance activities and can justify the value of current
activities and support the case for new initiatives. Justifying
the value of maintenance requires a significant investment in
time and energy to not only establish accurate measurement
parameters, but also to effectively communicate the value
of maintenance and its relationship to the company’s
underlying business goals. It involves shifting management’s
attitude from one that sees maintenance as a necessary
expense, to one that views it as a driver of profitability.
When using metrics to guide your project plans, it is
important to stay objective, stick to the facts and understand
the business trends that drive the need for improvements.
For example, how does your parts management program
help improve equipment uptime and reduce expenses
related to lost production and scrap?
If management does not fully understand the impact that
maintenance activities can have on the organization
and overall business performance, it is less likely they
will support new initiatives or additional expenses.
As for a management discipline, companies are
still striving to realize the full potential and benefits
of using performance metrics as a proactive tool to
implement optimal maintenance strategies throughout
their organizations. When approached with a clear
understanding of the production issues and business
goals, metrics can be a powerful way of establishing
baselines, setting targets, determining the appropriate
maintenance methods to reach those targets, and most
importantly, measuring success.
18
The emergence of advanced automation and control
technology has made it much easier to calculate and
analyze maintenance-related metrics and their benefits.
For example, maintenance software systems can track
spare parts, compile time and costs, schedule work
and analyze equipment conditions.
To be functionally and cost-effective, data gathering
capabilities should be designed into the automation
system itself whenever possible allowing metrics to be
calculated as part of normal production activity. It is also
often easier to implement and less costly to include metric
capabilities at system conception than at a later time.
However, all metrics cannot be automatically collected
and in practice, you will need a mix of both “hard”
and “soft” measures. Also keep in mind that automation
systems and software can’t guarantee good maintenance
performance or compensate for a lack of fundamental
knowledge of what to measure and why.
In some cases, companies can boost manufacturing
efficiencies through improvements in operational
processes, such as inventory tracking and equipment
repair management. An effective inventory tracking
system can help companies track overall repair rates
and identify ways to build efficiencies into the process.
For instance, if a pattern of
repairs occurs on a particular
machine over a period of time,
storeroom managers can work
with maintenance engineers to
find and repair the root source
of the equipment failure.
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MeasuringSuccess
About the author
Scott Teerlinck, Director of Commercial Marketing for Customer Support and
Maintenance Business, Rockwell Automation
Scott joined Rockwell Automation in 1994 as a sales engineer trainee and has held
progressive positions within the field sales organization including Global Accountfi
Team Leader for Eastman Kodak and Branch Manager of the Rochester, NY office.fi
In June 2005, Scott was named Director, Commercial Marketing for the Customer
Support and Maintenance (CSM) Business. His role includes leading commercial
marketing and business development resources that interface with Rockwell Automation
sales employees, customers, and channel partners. Scott is responsible for identifying
and implementing commercial strategies and programs to help grow market share,
improve CSM profitability, and promote customer solutions on a world wide basis.fi
He also leads CSM efforts to coordinate marketing and strategic activities between
CSM and the other Rockwell Automation and third party businesses.
Scott earned his MBA from the Rochester Institute of Technology and his bachelor’s
degree in electrical engineering from the University of Wisconsin-Madison. He is
located in Milwaukee, where he reports to Mike Laszkiewicz, Vice President,
Customer Support and Maintenance Business.
KEYMETRICS
Return on Net Assets (RONA)
This metric calculates how well a company
converts assets to sales, and therefore profits.
The simple calculation is Plant Revenue minus
Costs divided by Net Assets.
Overall Equipment Effectiveness (OEE)
OEE is a statistical metric for machine and/or
process efficiency. It is calculated by multiplying
Rate X Quality X Availability. The product is
the value a machine contributes to the
production process.
OEE >75% is pretty good, but don’t stand
still. Drive to world class: >80% for batch
processes and >85% for continuous processes
(Maintenance Technology, February 2006).
Availability This indicator quantifies ay
machine’s downtime and operating time. The
performance metric takes into account all of
the factors that cause the process to operate
at sub-optimal speed and aids in identifying
operational periods that are at risk from
equipment damage.
Uptime This performance metric captures a
percentage of scheduled uptime that is actually
available for a machine or process to operate.
Cost of Downtime Amount of downtime is
measured in hours of interrupted production,
while the cost of downtime takes into account
expenses or losses resulting from downtime,
including lost margin, unutilized direct and
indirect labor, and unabsorbed overhead.
Mean Time Between Failures (MTBF)
MTBF is the mean (or average) time expected
between failures of a given device and is
normally measured in hours. It is meant to be
applied to a large sample over a long period
of time.
Maintenance Cost per Output Unit
This metric is used to evaluate actual costs
against stated goals or against industry
standards. It is calculated by taking the total
maintenance materials and labor cost divided
by the total units produced.
To ensure long-term success, the impact of your maintenance strategy must be continuously
measured against defined production and business goals. You can choose from a wide range
of performance indicators to measure success. The definitions for some of the most common
indicators are shown below.
19

20
GETTING STARTED: CREATE A MAINTENANCE MAP
sample sketch
Instructions
ᕡ Using the worksheet to the right,
draw a rough sketch of the plant floor
(see sample sketch below).
ᕢ Identify the critical areas
of the plant with:
ᕣ Identify the Key Performance
Indicators (KPIs) for each area:
Productivity:
U Uptime / Availability
Q Quality
R Production Rate
Financial:
A
ᕤ Identify the top 1-2 issues that
impact how each area is measured.
ᕥ Label your “current” AND “desired”
maintenance approach for each
area of the plant.
Pd Predictive
Pv Preventive
Re Reactive
!
Before you can accurately measure the success of your maintenance strategy, you must ﬁrst determine if the
appropriate maintenance approach is being utilized in each production area. Follow the instructions below
to map your current maintenance strategy. If your current and desired approach do not match, you may
need to implement the desired approach before the right metrics can be obtained and properly analyzed.
For help mapping your process, or implementing your maintenance strategy, contact your local Rockwell
Automation sales ofﬁce. Go to page 56 for detailed information on the Rockwell Automation products, services
and support that can be utilized in your strategy.
!! vPv
Re
Pd
ReRe
Pv
ReRe
Pv
ReRe
UU
QQ
RR
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21
MeasuringSuccess
HART AND CALCULATE YOUR CURRENT OVERALL EQUIPMENT EFFECTIVENESS

MIXING AND GRINDING
Situation A new milling machine is being
designed and installed. Since the plant is
already functioning with its existing milling
machine, the design engineers aren’t directly
impacting production, although they need
to follow a design schedule.
Life Cycle Phase Design
Primary Staff Responsibility
Engineering Manager
Proper Maintenance Approach
A non critical part of a process with little
impact on production does not require
routine or predictive maintenance as long
as problems are addressed as they occur.
A reactive approach ensures that skilled
personnel can implement changes within
acceptable time limits. Access to support,
spare parts, and knowledgebases can help
facilitate this approach.
STRATEGIC MAINTENANCE
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 brewery 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.
BOTTLING AND PACKAGING
Situation The ﬁlling lines are essential toﬁ
the plant’s operation. These are the most
complex machines in the system and must
produce around the clock. The oldest line will
be upgraded soon, so consistent production is
needed to plan for this large expense.
Life Cycle Phase Replace
Vice President of Engineering and Operations
The failure/malfunction of complex equipment
often results in a high cost of lost production
and repair. To eliminate unplanned downtime,
or resolve problems quickly should they
predictive approach
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FERMENTING
Situation The ﬁltration tanks can more than handle theﬁ
capacity demands of the plant. These machines are not
complex but can be a bottleneck if they aren’t running.
As this part of the plant is about seven years old, failures
occasionally happen.
Life Cycle Phase Maintain
Maintenance Supervisor
This equipment has aged enough to be within the
Mean Time Between Failure (MTBF) common for
automation equipment (seven years). Because
bottlenecks could result in a high cost of lost production,
a good preventive approach is recommended.
A knowledgeable maintenance staff, supported by
domain experts and a responsive repair process, should
adequately address most issues.
BREWING
Situation More than enough lautering tanks were
installed a year ago, so only two of the three tanks
are used at a time. The OEM says there shouldn’t
be any problems with the tanks for at least 10
years if the pumps are greased regularly and the
operators rotate usage throughout the system.
Life Cycle Phase Operate
Production Supervisor
Newer equipment past its warranty can be
a problem if maintenance and rotations are
not established, but may indicate cost/budget
preventive approach cludes
IN THE BREWING INDUSTRY
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CUSTOMER SUCCESS STORIES FEATURING ROCKWELL AUTOMATION
24
This article originally appeared in:
Plant Services magazine
www.plantservices.com
“Integrating a predictive
maintenance program to
maintain equipment uptime
ensures customers get the
products they want, when
they want them.”
Controlling the
Compressor:
g
AIR LIQUIDEBy Mark E. Lawrence, P.E., CMRP, and George F. Hofer
Air Liquide Large Industries U.S. LP is part of Air Liquide
Group, which produces industrial and medical gases and is
headquartered in Paris. In the U.S., Air Liquide maintains more
than 125 production facilities and 700 customer installations
spread across some difficult to reach geographies. Before
2002, the U.S. company used a legacy vibration program that
was inconsistent in its application of technology and wasn’t
producing the desired results.
Late in 2002, Air Liquide partnered with Rockwell Automation
to provide vibration analysis services to 32 plants on a trial
basis. The program expanded quickly in early 2003 to include
vibration monitoring at 107 primary production facilities.
In August 2004, Air Liquide recognized the need to expand
its predictive maintenance (PdM) program to include oil
and infrared analysis, and again partnered with Rockwell
Automation. Air Liquide’s needs and aggressive long-
term strategy didn’t leave time for incremental continuous
improvement. The key program objectives included:
• Transitioning from legacy systems to
state-of-the-art information solutions
• Understanding how reliability affects
customer relationships and profitability
• Recognizing the need for uniformity of
predictive technologies
• Leveraging technology in geographically
challenging areas
• Analyzing results and setting goals
for improvement
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PRODUCTS AND SERVICES
C U S T O M E R
PROF I L E
25
“NOTONLYMUSTTHEREBEROBUSTMAINTENANCEPROGRAMS
TOENSUREHIGHRELIABILITY,BUTALSOAWAYTOSEEPROBLEMS
FARINADVANCESOARRANGEMENTSCANBEMADEFOR
EQUIPMENTDOWNTIMEWHENCUSTOMERDEMANDISLOW.“
Before 2000, maintenance and reliability
functions were decentralized as was the
responsibility for approximately 100
plant sites throughout the U.S. Since
that time, Air Liquide in the U.S. has
centralized these functions under a new
maintenance department and regional
reliability centers. The new department
deployed several new systems including
a maintenance management process,
a new computerized maintenance
management system (CMMS) and
preventive maintenance programs. Once
these basic systems were in place, the
department turned its attention to its
predictive maintenance programs.
Many of the sites used vibration, infrared
and oil condition monitoring, but
because no corporate standard existed
for applying predictive technologies,
individual managers had great discretion.
As a result, applications were inconsistent
and couldn’t be integrated. Similar data
was taken at different frequencies with
different tools and at different locations
for like equipment. Therefore, data and
reports varied in format and detail, and
information couldn’t be compared and
analyzed across similar equipment.
Because a company-wide CMMS didn’t
exist when these individual programs
were established, predictive findings
couldn’t be linked to traceable work
orders. Compliance of corrective actions
versus predictive findings was unknown.
Several dozen plants eventually coalesced
around a common vibration service
provider, but the program had several
problems. The contractor owned the
data it collected. While the contractor
provided some standard reports, Air
Liquide had to pay for ad hoc analysis it
could have performed itself. But, more
importantly, the contractor had only one
office in the far southeast corner of the
U.S. Given Air Liquide’s vast geography
in the U.S., more than 80% of the costs
the contractor charged were incurred for
travel to the plant sites. Air Liquide knew
there had to be a way to get greater value.
By 2001, the infrared scanning program
was probably the closest to being
national. Electrical standards had been
developed and applied, and an internal
resource was used for data collection
and report writing. While the program
was effective, it was used primarily for
electrical devices and didn’t include
any applications to identify process,
fixed equipment or rotating equipment
problems. And given Air Liquide’s
geographic dispersal and the travel
it required, having a single resource
dedicated to the program didn’t seem
viable in the long term.
Although it was implemented at
several sites, oil condition monitoring
was probably the least used of the
technologies. There seemed to be
significant potential benefits to
increasing its use.
TRANSITIONING FROM LEGACY SYSTEMS

26
“ W I N N E RS A N D LO S E RS I N O U R B U S I N ES S A R E D E T E R M I N E D
BY T H O S E W H O C A N P ROV I D E T H E M O S T R E L I A B L E P RO D U C T
AT T H E LOW ES T P O S S I B L E P R I C E… A N D O U R M A I N T E N A N C E
A N D R E L I A B I L I T Y P RO G R A M S H AV E A H U G E E FFE C T O N B OT H
S U CC ES S FAC TO RS.”
Many of Air Liquide’s products are commodities. The
company president once remarked, “Winners and losers
in our business are determined by those who can provide
the most reliable product at the lowest possible price…
and our maintenance and reliability programs have a huge
effect on both success factors.” Whether it’s nitrogen,
oxygen, hydrogen, steam or electricity, customers want
all of the product they want, when they want it, and they
don’t want to hear excuses why they can’t have it.
This places a premium on our unit availability and
equipment reliability. Not only must there be robust
maintenance programs to ensure high reliability, but also
a way to see problems far in advance so arrangements
can be made for equipment downtime when customer
demand is low. That’s why predictive maintenance
programs play such a large role in Air Liquide’s
reliability strategies, which play a significant role
in its business strategy.
Before the 1990s, Air Liquide was primarily an air
separation company that produced oxygen, liquid
argon and both liquid and gaseous nitrogen. These air
separation units could back up production to our largest
gas customers by storing large quantities of liquid nitrogen
and oxygen. We could then vaporize the liquid and
sustain several days of downtime in the event of an
interruption in service. The primary strategy for these
products was to reduce our mean time to repair (MTTR).
This meant focusing on stocking spare parts and having
resources ready to react to get a unit running again
before the “liquid ran out.”
Air Liquide also operates four large cogeneration u
nits near Houston to provide electricity and steam
to customers in the area. Because there’s no effective
way to store backup quantities of these products,
Air Liquide adopted a conservative maintenance
strategy that required significant costs and downtime
to ensure predictable uptime.
In the late 1990s, Air Liquide expanded its business
into hydrogen, a product that can’t be stored easily
in quantities needed to ride through any significant
downtime. In this business, our standard air separation
maintenance strategy didn’t apply because even small trips
caused huge problems for customers. Major breakdowns
could be costly for both Air Liquide and its customers. For
hydrogen, the conservative maintenance strategy we used
for cogeneration required too much planned downtime
to be feasible as a business strategy. The strategy had
to provide interruption-free production with optimum
downtime for planned maintenance.
In the meantime, a majority of our customers had already
embarked on their own never-ending journey to reliability
improvement. As they eliminated or improved their
internal reliability problems, the reliability of their gas,
steam and electricity suppliers gained greater visibility.
As our customers improved their reliability game, they
demanded more from suppliers. A world-class predictive
maintenance program was becoming an important
element of a critical reliability improvement strategy.
CUSTOMER RELATIONSHIPS AND PROFITABILITY

Measure
Collect
Analyze Report
Take
Action
PDM Cycle
C U S T O M E R
PROF I L E
27
UNITY OF PREDICTIVE TECHNOLOGIES
Implementing a world-class, best-practice PdM program
begins with identifying the required measurement variables
and appropriate technology for capturing reliability data.
For Air Liquide, the nature of the equipment monitored,
predominant failure modes and mean time between
failures necessitated using vibration, oil and thermographic
technologies. Failure modes, MTBF data and industry best
practices dictated a monthly interval for vibration data
collection, quarterly for oil analysis, and annually for infrared
thermography scans.
Before August 2004, the Air Liquide PdM program consisted
of a decentralized approach to vibration monitoring, oil
analysis and thermography. Neither a unified nor integrated
approach was used in managing the data. Reports and
recommendations weren’t linked to the CMMS or return
on investment data.
Improvements that started late in August 2004 have helped
Air Liquide demonstrate a truly integrated and successful
PdM program through the following steps:
• Standardized reporting process and information flow
• Centralized data storage and access through a
common Web interface
• Centralized PdM technologies, reports and analysis
• Recommendations and reporting linked to CMMS data
• An interface for live-time, closed-loop progress
measurement
Standardizing the reporting process and information flow
involved establishing a natural link between the reports
and recommendations submitted for vibration, oil and
thermography. This also included switching from oil and
thermography programs run by individual plants to a
single-source provider for the three technologies managed
at the corporate level.
Rockwell Automation provided a common platform for
integrating vibration and oil data, and partnered with
Predictive Service Corp. to provide infrared thermography.
A common reporting platform was established quickly and
used as a report-generation tool. The latter feature was an
application utility installed on each field service engineer’s
personal computer.
Because infrared thermography was provided on an annual
basis and generally only used for electrical components,
this technology was linked via the Web interface only.
Rotating equipment is added to the thermography scan
when exceptions are noted in vibration and oil.
Centralizing the data storage into a common server platform
enabled Air Liquide to leverage the CMMS database, PdM
software database and information from the interface
for reporting vibration, oil and thermographic scans.
Once in place, a Web interface formed a dynamic link
among the three data repositories, and measured
and displayed program success.
Incorporating analysis data from
each predictive technology
ensures that asset health can be
evaluated completely. Because
each technology has a different
monitoring interval, we ensured
that oil samples were taken when
field service engineers were taking
vibration data.
When lab results are reported, oil condition
data is added to the PdM database and incorporated
into the overall recommendations made regarding asset
health. Viscosity, wear particle analysis (WPA), analytical
ferrography and other diagnostics are reported along with
vibration data for complete machine condition status.

28
(UNITY OF PREDICTIVE TECHNOLOGIES CON’T)
Since January 2005, we identified more than 148 cases of
viscosity breakdown or improper lubrication. In at least
five cases, WPA revealed significant particulate counts in
conjunction with increased vibration measurements.
Follow-up samples verify that proper lubrication was restored
and machinery repairs have been made. A direct link to the
recommendation and repair action taken enables these to be
tracked and linked to PdM program performance (right).
Linking recommendations from the three PdM technologies
with the computerized maintenance management system
established the basis for measuring PdM program success.
Once completed and properly distinguished, key PdM
program performance indicators are tracked and measured
on a real-time interface. ROI data is linked directly to
individual facilities, by zone, by business class, and even
summarized as a whole for Air Liquide senior management.
A Web interface gives senior management a “status at a
glance” indicator. This requires properly classifying work
orders and entering financial data into each action taken
from PdM recommendations. Leveraging the capabilities
of our CMMS, each PdM work order entered was classified
using the following critical components:
• Work class: “PDM” denotes any work order initiated as
a direct result of a PdM program recommendation
• Activity type: Denotes predictive technology used to
identify problem using one of four tags: “Predictive, Vib,”
“Predictive, Oil,” “Predictive, IR” or “Predictive, Elec”
• Actual repair cost: Installation and repair cost of
repair required
• Estimated savings: The reliability engineer’s evaluation
of problem reported and potential cost savings averted
by avoiding catastrophic failure
• Failure class: Type of machinery affected: motor,
compressor, etc.
• Problem code: Detailed definition of problem component;
e.g., coupling failure
Developing the interface for monitoring real-time progress
of maintenance work orders and PdM recommendations
involved leveraging the existing CMMS database backbone
and the centralized database storage architecture. Partnering
with Predictive Services, Rockwell Automation designed
and developed a Web interface capable of supplying a
PdM Web management tool for tracking the closed-loop
PdM process. The interface links, tracks and reports
progress of any maintenance action initiated from the
PdM program technologies.
This tool enables senior management to track program
KPIs, maintenance activity bottlenecks and overall program
effectiveness quickly and efficiently.
Fundamentally, the PdM program’s integration and unity
established a direct link between maintenance repair
recommendation and maintenance action taken. It
permits measuring and tracking financial data, metrics
and program success to provide ROI. Unless a direct
correlation is established between maintenance action
taken and recommended repair, program success can’t be
measured fully. An overwhelming majority of PdM programs
fail because they lack this tie, and work orders and repairs are
made without regard to the PdM recommendation.
Classifying work
orders properly
is another measure
that connects
maintenance
to ROI.
High-level statistics alert system users to problem trends.
Data Analysis Reporting Tracking
Action
Vibration
ROI
Problems
Sides
Samples
MTBF
Saves
Oil Analysis
Thermography
Feedback

29
C U S T O M E R
PRO
F I L E
WHERE THE EFFORT WENT
MAXIMO WORK ORDERS
Predictive, Vib 267
Predictive, Oil 114
Predictive, IR 158
Predictive, Elec 89
Total PdM W/O’s 628
Figure 6.
Screen capture of the Web interface.
LEVERAGING TECHNOLOGY
Managing maintenance activities on a national level is a challenge many large organizations
face. Geography and disparity of equipment implementation and plant design makes stocking of
spares and planning maintenance activities difficult. Many OEMs, suppliers and key contractors
have equipment in the field that will ultimately require maintenance.
Implementing a system capable of tracking manufacturer type and reliability information
simultaneously enabled Air Liquide to isolate problematic equipment manufacturers. This
information can be used in supply-management negotiations and, more importantly, designing
and engineering new plant construction. By leveraging the
Web-based technology and interface, any reliability center
manager, reliability engineer or maintenance technician can
search and sort reliability problems by manufacturer type,
equipment type or installed locations. We can do this at the
plant level, by zone, business class or summarized for Air Liquide
overall. Leveraging this data during contract negotiations can
save Air Liquide a significant amount of time, money and effort.
Linking this interface to data in the CMMS database and PdM
software database also enables better management of reported
problems. Before visiting any Air Liquide facility, a preventive
maintenance work order initiates data collection in the CMMS. Any recommended repair
or follow-up work generated as a result of the PdM visit is then classified as a PdM work
order type, linked to the PM work order and distinguished with the appropriate activity type
and problem.
Because follow-up work orders are linked to the original PM visit, reports reveal if any follow-
up work was completed. This enables better tracking of problems throughout the approval
process, enables reliability engineers to budget appropriately and empowers the PdM engineer
with the results of closing the loop.
The bidirectional gateway and exchange of data between the PdM software database and the
CMMS database is another example of leveraging technology to substantiate program success.
Figure 6 shows a direct correlation between vibration data and work completed. The dynamic
link enables up-to-date status information and the resultant cause/effect on newly acquired
PdM data.
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Figure 7.
30
ANALYZING RESULTS AND SETTING GOALS
Aligning the PdM program vision statement with monthly tracking metrics (KPIs) establishes
an overall indicator of the relationship among Rockwell Automation, Air Liquide and contract
performance. KPIs are reviewed in the form of a monthly compliance report submitted
to supply management and reviewed with the senior maintenance and reliability team.
Because KPIs are reviewed monthly, PdM program success is tracked and recorded to justify
program savings and ROI data. An example of the monthly compliance data and KPIs for
Air Liquide include:
• Sites visited • Samples taken • PdM saves • Warranty claims
• Customer care issues • Program costs and payment information
Because each technology is a unique component of the overall PdM program, and work orders
can be classified as such, further detail and tracking of individual PdM saves can be measured on
a monthly and year-to-date basis. Figure 7 represents a breakdown of PdM activity by type for
the period from August 2004 through August 2005 (one year of implementation).
Also, we track and measure work order compliance to ensure the program derives actionable
repairs from the PdM program recommendations. This variable is a measure of the number of
new problems reported versus work orders initiated. Tracked by month, Figure 8 shows an
example of one reliability zone.
Future goals include tracking and monitoring turbine efficiency and machine performance
as well as refining ROI data. One capability currently being implemented is the addition of
pressure, flow and temperature measurements to the PdM program vibration routes. The PdM
software uses these variables to calculate thermal and mechanical efficiencies. Trending can
then be used to predict expander replacements based on efficiency savings.
The partnership between Rockwell Automation and Air Liquide provides benefit to both
Air Liquide and its customers. For starters, the nearly 2,000 interventions before equipment
breakdown have avoided countless unit shutdowns. This isn’t only a benefit to our customers.
It saves Air Liquide considerable costs by attacking problems while they’re still relatively small.
However, this is just the start of what can be done with better information.
AUGUST ‘04 - AUGUST ‘05 PDM DATA
30%
17%
3%
50%
Vibration
Oil
IR
IR Compliance

C U S T O M E R
PROF I L E
31
Mark E. Lawrence, P.E., CMRP, is Director of Maintenance and Reliability
at AirLiquide Large Industries U.S. LP in Houston, Texas. Contact him
at mark.lawrence@airliquide.com and (713) 624-8585.
George F. Hofer is Corporate Program Manager at Rockwell Automation in Houston,
Texas. Contact him at gfhofer@ra.rockwell.com and (713) 402-2288.
0
40
80
120
140
100
60
20
160
2004-08 2004-09 2004-10 2004-11 2004-12 2005-01 2005-02 2005-03 2005-04 2005-05 2005-06 2005-072004-09 2004-10 2004-11 2004-12 2005-01 2005-02 2005-03 2005-04 2005-05 2005-06
■ CANCELLED 1 2 1 1 6 34 4 0 0 0 1 02 1 1 6 34 4 0 0 0 1
■ COMP 51 78 75 51 35 123 108 145 153 106 112 11778 75 51 35 123 108 145 153 106 112
■ PAST_DUE 1 1 2 1 3 0 1 3 6 8 0 41 2 1 3 0 1 3 6 8 0
TOTAL 53 81 78 53 44 157 113 148 159 114 113 12153 81 78 53 44 157 113 148 159 114 113
COMP 96% 98% 96% 96% 80% 78% 96% 98% 96% 93% 99% 97%96% 98% 96% 96% 80% 78% 96% 98% 96% 93% 99%
Past_Due Cuma 19 6 7 5 7 6 7 4 9 15 15 1819 6 7 5 7 6 7 4 9 15 15
One can now look across common equipment and determine which
OEM provides equipment with the lowest levels of vibration. Couple
this with work order and reliability data from the CMMS, and we can
provide quantitative information about what equipment to buy to
improve MTBR.
We’re getting to the point where, armed with data and information
that gets to the root of our problems, we can call in an OEM to discuss
equipment issues. Instead of anecdotal opinions driving the discussions,
the information from our systems now allow us to focus on improving
long-term reliability.
Any engineer, specialist or expert, anywhere in the world, with access
to our Internet site, can look at data and information on any piece of
equipment in the U.S. and can help us troubleshoot problems at even
the most remote sites.
No, we haven’t completely eliminated unplanned breakdowns, but these
events are becoming fewer and fewer and have set the stage for even
better reliability for our customers and shareholders in the years ahead.
Figure 8.
“ANY ENGINEER,
SPECIALIST OR EXPERT,
ANYWHERE IN THE
WORLD, WITH ACCESS
TO OUR INTERNET SITE,
CAN LOOK AT DATA AND
INFORMATION ON ANY
PIECE OF EQUIPMENT”
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ROCKWELL AUTOMATION
SUPPORT SPECIALISTS TELL
YOU HOW TO MAINTAIN
YOUR AUTOMATION
EQUIPMENT TO OPTIMIZE
PERFORMANCE AND UPTIME
Troubleshooting an
Ethernet/IP™
System
When troubleshooting any EtherNet/IP™
system, you
must have a logical order to troubleshooting. The
order for each troubleshooting issue is dependent
on the details for that issue.This TechTip will list and
detail, in order of priority, the troubleshooting steps
for EtherNet/IP systems.
When troubleshooting Ethernet/IP systems, there are
potentially many possible troubleshooting scenarios.
In general, there are three types of problems:
• It does not work at all
Examples: an I/O node is not connected to a
switch (missing cable), cannot ping a node, all MSG
instruction to a specific Allen-Bradley®
1756-ENBT
ControlLogix®
EtherNet/IP Module fails.
• It works but is too slow
Example: A resource (PC, controller, 1756-ENBT)
in the system is overloaded.
• It works but fails intermittently
Examples: The ControlLogix controller outgoing
unconnected message buffer is being exceeded,
Noise is causing an I/O connection to be lost.
Resolving the Problem
To resolve any of the above problems, you need to
know where to look and what to examine. Check
all of the following carefully as possible sources
of the problem:
• slow PC or slow application running on the PC
• node configuration (IP address, etc.)
• congested network (lots of traffic such as broadcast)
• slow network (satellite or frame relay)
• misconfigured switch or router
• Logix controller resources
- controller processing capability
(5550, 5555, 5563)
- timeslice for communications
- cached message queue (32 max)
- unconnected outgoing buffers (40 max)
• insufficient processing capability in an
ENBT module
• duplicate IP addresses
• defective Ethernet network hardware
(e.g., cable, switch port, or ENBT module)
• web server diagnostics or RSLinx®
diagnostics
If you have addressed all the above issues and are still
experiencing problems, noise could be the cause.
The steps below will provide general information to
resolve any of the above problems.They do not detail
individual troubleshooting possibilities.
The steps can be categorized as follows:
• It does not work at all
See Intermittent/No Response, Physical Layer
• It works but is too slow
See Logix Controller System Overhead, Module
Device Capacity, I/O or Produce/Consume Tags,
Rockwell Automation Ethernet NIC, Logix Controller
outgoing unconnected message buffer, etc.
• It works but fails intermittently
See Switch configuration, I/O or Produce/Consume
Tags, Logix Controller unconnected message buffer, etc.

33
Step 1: Intermittent or No Response
You may see the following when there is intermittent
or no response:
• “Request timed out” could result from numerous
issues including target is powered down.
• “Unknown host” means the specified IP address
is bad, e.g., 255.255.255.255.
• “Destination host is not reachable” could result from
numerous issues including a bad cable.
When any of the above occur, check for the following:
• AC power not applied
• A missing or defective cable (a clue would
be that the Link light is off or intermittent)
• You did not configure the module
• You did not completely configure the target node
– including subnet mask and gateway
Example: attempting to ping a module on a
different subnet, and the subnet mask is set
incorrectly or the gateway address is incorrect.
• On some switches (e.g., Cisco 3550), port mirroring
disables pinging (on the “mirror-to” port)
If replies are intermittent, ping continuously and
record the deviation. If the jitter is more than
10ms or you skip a reply:
• Something is busy (network or NIC)
However, a busy 1756-ENBT probably won’t be
the problem. From measurements, a 1756-ENBT
running at 100% CPU Utilization replies in the range
10-16ms. If you find a heavily loaded interface, reduce
the load to 90% or less to allow for some margin.
• The network is long (satellite or Frame relay)
• Noise is corrupting packets, and they are
being dropped
Example: ping –t 130.130.130.1
This will ping continuously
If you can ping successfully, but the problem is
not solved, continue with the next steps. For
help with the Ping command, just enter Ping
from a cmd screen (DOS screen).You could also
use RSWho to test connectivity. However, ping is
simpler to use and faster.
Step 2: Bad Hardware
If communications are consistently bad, replace suspect
hardware to isolate the trouble area. Problems could
include cables, the Rockwell Automation Ethernet
interface (e.g., 1756-ENBT) and switch port.
The problem may also be old firmware or hardware.
Record hardware and firmware versions and contact
the appropriate vendor for update information.
Step 3: Switch Configuration, Autonegotiation
or Hard-configuration
The autonegotiation specification (in the 802.3
standard) allows for interpretation by developers.
The result is every vendor’s Autonegotiation
firmware has similar, but not identical, functionality.
If one node is configured for half-duplex and the
other for full-duplex, random and possibly frequent
communications will be lost.
To see the Rockwell Automation duplex/speed status,
see Rockwell Automation web server diagnostics,
Class 1 Packet Statistics. Verify that the status reported
matches the switch configuration.
Example: If your switch is configured for
Autonegotiation, the Rockwell Automation web server
page should indicate Autonegotiated speed and duplex.
If you are running out of troubleshooting ideas, hard
configure the speed and duplex on the switch ports
and also on all Rockwell Automation nodes.This will
eliminate one more variable.
With RSLogix™ version 12 software, you can hard
configure speed and duplex. RSLinx version 2.41
software (build 10) does not yet support this feature.
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.
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Step 4: I/O or Produce/Consume Tags
(class 1 messaging)
Look at Missed Frames in the web browser diagnostics
(see detailed web server description in Step 12). This
parameter is only for I/O or produce tag messaging.
Although some applications may still run when losing
frames, you should strive for a system with zero (0)
dropped frames.
Furthermore, if you are dropping at least four
consecutive frames, you might be dropping a CIP
connection. If you are dropping connections, this will
definitely be incrementing. If you are not dropping
connections, this may be incrementing if your system is
not as stable as possible.
Viewing Missed Frames will help quantify a problem.
The yellow triangles in the RSLogix 5000 software I/O
Configuration tree will not be seen if a connection is
lost and recovered quickly. However, the Missed Frames
counter will see everything – even one missed frame.
This counter is excellent for diagnostics because of its
high resolution.
Step 5: EtherNet/IP Module Device Capacity
Use the web server to verify that CPU utilization on the
Ethernet NIC is less than 100%. If utilization is at 100%,
this may be the problem.To reduce the utilization:
• Make I/O RPI values larger (slower)
• Reduce the number of I/O connections
• Make non-critical traffic less frequent
(e.g., MSGs and HMI)
• Add another EtherNet/IP module and
divide the traffic load
Step 6: Logix Controller Outgoing
Unconnected Message Buffer
ControlLogix controllers have a limit of 10 outgoing
unconnected buffers.As of version 8, this can be
increased to 40.These are required for all messaging -
explicit and implicit to establish a connection.
If the controller tries to exceed this limit, it will fail.
For example, if you try to initiate 50 MSG instructions
simultaneously, those in excess of the buffer size will
fail. See the Rockwell Automation Knowledgebase
document G20181 for information on reading
unconnected outgoing buffers.
attribute 17 is reserve (unused)
attribuite18 is high-water mark
attribute 19 is buffers currently in use
Use RSLogix5000 version 12 software to read
the above values reliably.
Step 7: Logix Controller System Overhead
Add more time for communications by increasing the
continuous task timeslice or run the higher priority
tasks (e.g., Periodic) tasks less frequently or at a lower
priority.The default timeslice is 10%.Try increasing
it to 30-50%.
Step 8: Slow PC Application
If your application is running slow, there are two
possible reasons:
• The PC is underpowered
• The application runs slowly
(or accesses controller data inefficiently)
In either case, look at the CPU utilization in the
Windows®
Task Manager to see how close it is to 100%.
You can also stop the application and use OPC test
client (included with RSLinx software) to access all
the data you need. Configure the topic poll rate for
1ms to operate it at the same speed as the Rockwell
Automation controller(s). If you can achieve sufficient
throughput using this approach, the problem is likely
the application itself or an underpowered PC.T
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Step 9: Duplicate IP Address
If two Rockwell Automation nodes are duplicated, the
last one to be configured will “steal” the IP address.
When this happens, detection can be simple or difficult:
• Simple Detection
In the I/O tree, a 1794-AENT adapter is configured
and operating well. However, a 17560ENBT module
is then accidentally configured for the same address.
When this situation occurs, the Logix controller
declares the connection to the AENT adapter is lost.
• Difficult Detection
Messages (MSG instruction) from one ControlLogix
controller to another are occurring.Then, after a third
device is configured, the MSGs are failing. If you
ping the IP address, it will ping OK. If the 3rd device
is of the same type (e.g., 1756-ENBT) but does not
have the desired tag, even RSWho will show good
connectivity but the MSG will fail.
Work is in progress within ODVA EtherNet/IP to
examine a standard mechanism to detect and defense
against duplicate addresses.
Step 10: Network Trace
If you have yet to solve the problem, you need to
examine the network.Take a trace of the network and
analyze it for problems. If you are unable to do this,
Rockwell Automation can provide assistance through
our Network Services and Remote Support (see the
Products, Services and Support section in the back of
this publication for information).
While waiting for an analysis of the trace, you can look
at the physical layer (see below).
Step 11: Noise or Intermittent Defective Hardware
If the preceding steps do not solve the problem,
noise or bad hardware is the problem. Intermittent
communication is most likely caused by one of
the following:
• Ethernet cable placement (visually inspect for cable
placement next to 480VAC).
• Noise/grounding (physically detach an intermittent
chassis from the enclosure and see how it operates).
• Intermittent hardware (focus on a communications
problem between 2 nodes and try the following:
replace a Rockwell Automation Ethernet interface,
move the cat5 cable (from a Rockwell Automation
node) to a different switch port, replace an
Ethernet cable.
Step 12: Web Server Description
From the Rockwell Automation web server home page,
the following parameters have proven useful when
troubleshooting a system on one of the following modules:
1756-ENBT, 1788-ENBT, 1794-AENT, 1769-L35E (Other
Rockwell Automation EtherNet/IP products currently do
not use them but may in the future.)
In the Address field of Internet browser, enter the IP
address of an Ethernet interface module (e.g.,10.88.76.96).
You will see something similar to Figure 1.
Since it is probably the busiest, the Ethernet interface(s)
within the controller chassis is where you should begin
troubleshooting (as opposed to your other Rockwell
Automation Ethernet modules such as ControlLogix,
Flex I/O, etc.).
How many errors are too much? The answer to this
question is application dependent. For example, if
you have a single bad UDP checksum (caused by
electrical noise) every 100 packets, that packet will be
discarded. Some may say this not a problem because
the production line is running fine. However, to others
this is unacceptable.
Figure 1
This page is self-descriptive and useful
See figure 2.
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Step 12 Continued
Up to this time, most requests for troubleshooting involved
the I/O and produce tag. The diagnostics most useful I/O
and produce tag are marked with an asterisk (*) below.
Backplane Statistics - Identifies backplane errors.
Connection Manager Statistics - Identifies if any Rejects or
Timeouts are incrementing. Note: you can get the same info
from RSLinx by right clicking on the Ethernet module and
selecting Module Statistics and selecting Connection Manager.
Ethernet Statistics – Identifies Input/Output errors
TCP Statistics - Displays connection requests (outgoing from
the controller thru an ENBT), connection accepts (incoming
from the wire through an ENBT to a controller.These will
increment while you are online with a web browser), and
discards (bad packets that have been discarded)
UDP Statistics - This screen will increment only if other
devices are sending non-CIP UDP packets to this module.
At this time, no devices send non-CIP UDP packets to
this module.
From testing with a produced tag (RPI=10ms), the total
UDP packets and input UDP packets do increment (on the
company network) but they increment at a rate of only 1-3
every 10-30 seconds. With an RPI of 10ms, the produce tag
rate is 200 packets per second. The conclusion is that there
is no relationship between CIP packets and UDP statistics.
Without connecting Sniffer to investigate, the assumption
is that someone in the building is sending multicast to all
stations, including my ENBT module.
Also, the addition of CIP UDP checksum errors has formally
been requested.
Encapsulation Statistics - Shows cumulative and active in/
out TCP connections used for encapsulation (CIP) sessions.
The TCP statistics shown are for all TCP connections
(e.g., CIP+ HTTP+ telnet, etc.).
Enet/IP (CIP) Statistics - Active Class 1 Transports provides
the number of transports. In general, two (2) class 1
transports equate to a connection. Use this number to
verify against your calculated class 1 total.
Class 3 transport information is supplied including client
(outgoing) and server (incoming) details.
Unconnected message information is also provided.
The UCMM Worst Backlog (Client) can be used to see
the unconnected message high-water mark for messages
to legacy PLCs. If this value is 10 and you have the Logix
processor configured for a maximum of 10, you may be
trying to exceed the controller’s limit.
Class 1 (CIP) Packet Statistics
• Link Status* (including negotiation description)
• Speed*
• Duplex*
• Method for selecting duplex and speed*
(e.g.,Autonegotiation)
• CPU Utilization Percentage*
(includes processing for everything on the module)
• Current TCP connections (for all connections, class 1
and class 3, includes actual connections and ones
being built but not yet complete)
• Current incoming TCP connections
(these are for all connections, class 1 and class 3)
• Current outgoing TCP connections (for all connections,
class 1 and class 3, includes actual connections and ones
being built but not yet complete)
• Actual class 1 packets per second* (for I/O and produce
tag only, compare your calculated value to this number)
• Reserve Class 1 capacity (displays how much is unused)
• Total Missed Class 1 Packets* (for I/O and produce tag only)
Class 1 (CIP) Active Transports* - You should see only the
RPIs you configured (e.g., If all your configured RPIs are
50ms, you should see only 50ms API).
Class 3 (CIP) Active Transports - For explicit messaging,
transports are the same as connections. Examine the remote
addresses.Verify that these are correct for your system.
Examine the number of Class 3 transports.The number
of transports expected depends on what you are doing.
Examples include:
• RSLogix 5000 opens one CIP connection.
• A PanelView™
Plus can use one or more depending on
the volume of tags on scan.With 488 tags on scan (120
integers, 120 dints, 128 reals, 128 bools), a PanelView Plus
(actually RSLinx Enterprise) opened three transports.
Figure 2

37
Using the New RSView®
SE
Backup Utility to Make a Copy
of a Running HMI Server
Previously, backing up an HMI server was done
manually by running a bat file in a LocalSystem
DOS command prompt.
This method made it difficult to configure for
custom HMI project locations.As a result, it was not
conducive for automated backup processes, nor easy
to troubleshoot.A newer HMI backup utility with a
graphical user interface should be used instead of
the BAT utility.This utility is available for download
through the Rockwell Automation Knowledgebase at
http://domino.automation.rockwell.com/applications/kb/
RAKB.nsf/WebDocs/A102052574.)
The new utility has been developed to provide an easier,
more intuitive step-by-step backup process.Another
feature of this utility supports command line operation
when used with user configurable (CFG) parameter
files. For this utility to function correctly, the RSView SE
HMI server product files must be installed on the
same machine.
To install the utility, follow the steps below:
1. Uninstall (delete) any previous version of this utility
from your hard drive
2. Unzip the A102052574EXE.zip file downloaded from
the Knowledgebase to any path location on your hard
drive.This file includes all files necessary for the newer
HMI backup & restore executable.All files must be
installed to the same directory folder. Note: this version
utilizes a new component “Rockwell HMI Backup
Server.exe” that runs as a service - register this service
according to the installation instructions included
in the utility’s Help file (A102052574DOC.zip - also
downloadable from the Knowledgebase).This
Help file provides a step-by-step configuration and
usage description.
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Step 13: RSLinx Diagnostics
From RSLinx, in RSWho, you can right click, select
Module Statistics and select the tabs/links listed below.
• Link name: General (this tab is self-descriptive)
• Link name: Port Diagnostics
Most of this information can also be found in the
web server in the following places: Diagnostics
- Ethernet Statistics, Diagnostics - TCP Statistics,
Diagnostics - IP Statistics.There is often more
information in the web server but you must look in
three different places to see everything.Additionally,
RSLinx Port Diagnostics shows some values (e.g.,
alignment errors) that are not seen in the web server.
It is recommended you look at RSLinx Port Diagnostics
and note any errors.
• Link name: Connection Manager
(Same as Connection Manager in web server)
• Link name: Backplane
(Same as Backplane stats in web server)
References/Additional Resources
1. Noise
• EtherNet/IP Media Planning and Installation Manual
(Publication ENET-IN001A-EN-P)
• Industrial Automation Wiring and Grounding
Guidelines, 1770-4.1
• GMC-RM001www.ab.com/manuals/gmc/
GMC-RM001A-EN-P-JUL01.pdf
2. System Planning and Module Capacities
• EtherNet/IP Performance and Application
(Publication ENET-AP001C-EN-P)
Windows is a registered trademark of Microsoft Corporation
in the United States and other countries.
To download the above publications, go to:
www.rockwellautomation.com/literature and
search publication number or title.

USTRY EXPERTS
ANSWER
YOUR QUESTIONS
38
Q How do I determine which
Rockwell Automation e-Learning
products will help me obtain the
knowledge required to maintain
my automation equipment?
A First, select the appropriate Rockwell Automation e-Learning
course based on your learning requirements.To view available
courses, go to www.rockwellautomation.com/services/training.
The next step is to determine licensing options based on the
preferred delivery method (CD or Web) and number of users
(single user or multiple users).
RSTrainer®
Software on CD
The single user license for RSTrainer software on CD provides
access to one individual at a time.A single user license can
only be installed on one local computer unless a dongle is
purchased to enable moving the software license from one
computer to another.
Enterprise server licenses are designed for multiple users
(five minimum) and offer concurrent access to the RSTrainer
software. Companies of all sizes find this network solution to
be a great way to manage and use the RSTrainer e-Learning
suite of courses.
Web-based Training
A web-based license is designed for single user access to
Rockwell Automation University Online delivered via the
Internet.This single user license provides access to one
Rockwell Automation online course for 12 months.
Course availability is 24x7x365.

39
Q What automation-related
technical certifications are
available for individuals
to achieve?
A The Controls and Networks Certified Professional designation
identifies an exclusive group of proven professionals who have
demonstrated exceptional technical competencies and expertise
in the area of Rockwell Automation controls and networks.
Individuals participating in the certification program are
required to demonstrate their skill, knowledge, and mastery of
controls and networks by successfully completing a proctored,
online knowledge-based exam and hands-on application project.
The opportunity to become a Controls and Networks Certified
Professional is open to all individuals who have experience
using Rockwell Automation controls and network technologies
in their business. Controls and networks pre-tests are available at
www.rockwellautomation.com/services/training/access.html to
help you pre-qualify yourself for either the certification online
exam or the preparatory course, Controls & Networks System-
Level Integration (not a requirement for certification).
For additional information on technical certification,
go to www.rockwellautomation.com/services/training/
certification.html.
Q How can I ensure the new skills
acquired by my staff through a
training program are effectively
transferred to the plant floor?
A There are some fundamental practices you should consider to
maximize the effectiveness of any training investment. First,
verify that your employee meets all prerequisite knowledge and
skills identified in the course description.There is nothing more
frustrating for the student and instructor than someone trying
to learn new skills when “the basics” are lacking. Students lose
confidence in their ability to keep up with the other prepared
participants and never gain strong competency in the new skill.
Second, schedule training at the right time.Timing is everything.
Try to schedule the training as close to the anticipated need for
the newly learned skills in the work environment.An individual
can have an excellent training experience, but a long delay
between training and on the job performance may degrade their
skills and confidence.
The final suggestion to maximize training effectiveness is to
carefully select the training curriculum for each staff member
that will provide the skills and knowledge most relevant to
his/her job function. Select training courses that identify the
target audience, list job tasks practiced in class, and contain
content that matches your employee’s job responsibilities.
An “information dumping” course slows down successful
performance because the employee has to determine what
task is relevant to their job, when to perform the task and in
what sequence to perform the task.
Rockwell Automation can help determine the correct training
curriculum through an Integrated Performance Assessment. For
more information on Integrated Performance Assessments, go
to www.rockwellautomation.com/services/training/integrated.
html.Two online tools are also available to help determine the
courses that will be the most beneficial. To use these tools,
go to www.rockwellautomation.com/services/training/tool.
html (course selection tool) or www.rockwellautomation.com/
services/training/techareas.html (curriculum maps).
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Q & A
Q What are some of the
maintenance benefits of an
integrated control architecture?
A An integrated control architecture can have many maintenance
benefits. Some of the primary maintenance benefits of the
Rockwell Automation Integrated Architecture include:
Improved plant reliability with XM Condition Monitoring
Our XM®
Overall Machinery Protection Modules can process
in real time the critical parameters used in assessing the
current health, and predicting the future health, of industrial
machinery – providing machinery protection where needed,
and reducing downtime.
Multidisciplined control with the Rockwell Automation Integrated
Architecture provides a single control infrastructure for the entire
range of automation applications, including discrete, motion,
process, batch, drives and safety.
No longer must you work with a multitude of different controller
types, software types, language types and communications issues.
Redundancy, batch and other functionalities are all available.
Moreover, users can reduce training and equipment stocking
costs, reduce downtime and maintenance costs and improve
production by using common architecture and equipment
across the entire plant.
Reduced Downtime with Diagnostics in Kinetix Integrated Motion.
Motion control is often used in critical high-speed machines in
production operations. Using Integrated Architecture, you can
easily monitor the health of your control system and be alerted
to potential problems before they cause production to stop.
Improved Network Integration and Information Sharing
through NetLinx Open Network.
Your ability to collect and share data in the automation
environment is a critical component to the success of
your maintenance strategy.
Many plants already have a number of networks installed
for different purposes – but with the wide range of devices,
networks and protocols, it’s difficult to get all systems to
share data. The additional programming takes time and
requires complex integration – requiring significant startup/
troubleshooting, consuming valuable computing resources
and impeding the ability to react to change quickly.
Network solutions from Rockwell Automation form a seamless,
integrated open architecture called NetLinx. It is the best
architecture for complete bridging and routing of control
information and data. NetLinx integrates all the components in
an automation system and doesn’t require any programming
to integrate multiple networks – reducing installation time and
costs, simplifying maintenance and expandability. . . lowering
your overall risk.
Continued on page 41
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41
Q What are some of the
maintenance benefits of an
integrated control architecture?
Continued from page 40
With NetLinx, you can select components and media according
to your specific application with choices like EtherNet/IP™
for information and control, ControlNet™
for deterministic
control, and DeviceNet™
at the device level (also in
conjunction with FOUNDATION fieldbus for process
applications). All networks use the open international
Common Industrial Protocol (CIP) standard and share a
universal set of communication services that enable you to
move data across multiple networks effortlessly.
Reduced Repair Time through Auto Device Replacement (ADR)
Intelligent devices like drives and motor starters need to be
installed correctly to operate correctly. With Auto Device
Replacement (ADR) technology, available only through the
Integrated Architecture from Rockwell Automation, you can
dramatically reduce lengthy set-up time when replacing
damaged equipment. Our intelligent motor control, drives, soft
starts and electronic overloads support ADR functionality.
The Integrated Architecture solution for device replacement
requires just two simple steps:
1. A brand new unit is sourced straight from stores to replace
the damaged unit.
2. The DeviceNet scanner automatically sets the correct
node address and downloads the original device parameter
configuration. Device operation is restored with a minimum
of downtime.
The Integrated Architecture solution virtually eliminates set-up
time and can decrease defective module replacement time by
30 minutes or more. The Integrated Architecture solution also
provides the following benefits:
• Minimizes maintenance staff burden, unplanned downtime
and subsequent lost production
• Eliminates the need for a computer with configuration
software to replace a failed device
Q Is there a simple solution to
monitor my control Ethernet
network performance so I can
proactively identify problems
before production is affected?
A The Rockwell Automation Ethernet Diagnostics Module
(catalog number 9300-8EDM) can monitor network traffic
levels and send traffic level alarms directly to the control system.
The control system can then automatically alert maintenance
personnel as well as execute program functions based on the
network conditions.
For more information on the Ethernet Diagnostics
Module, go to www.rockwellautomation.com/services/rmd/
enetmodule.html

42
Q How does Intelligent Motor
Control protect my motors
from overheating in the event
of a conveyor jam better
than conventional overload
protection?
A An Intelligent Motor Control solution not only protects your
motor assets from damage, it controls and communicates the
information before the event occurs.The built-in intelligence of
an E3 Plus electronic overload relay in an across-the-line starter,
SMC-Flex soft-starter or PowerFlex®
variable speed drive provide
the predictive diagnostics and alarm warnings to help prevent
your motor from over-heating, minimizing costly downtime.
Conventional overload protection requires a wide range of
devices wired together and lack the communication capabilities
that can predict a fault.When a motor is in a state of severe
exertion, beyond its safe operating limits, the electronic motor
overload feature in an Intelligent Motor Control solution can
reduce the output current or shut off the motor and protect it
from thermal damage or catastrophic failure.Thermistor feedback
taken directly from the motor windings use actual temperature
readings to determine motor stress. Motor overload software uses
an algorithm incorporating motor current, speed, and time as
inputs to model the temperature of the motor.Warning settings
then alert operators to potential problems before a failure occurs.
The advanced communication of DeviceNet™
, ControlNet™
and
EtherNet™
shares this information with the control system to
provide alerts, warnings and reminders to personnel throughout
the plant or even remotely.With Intelligent Motor Control
you not only prevent undue maintenance to your motors, you
increase your production uptime.
Q & A
Q Can my maintenance engineers
use a modem to access our
control systems when they are
not on-site?
A Yes. However, not all modems are created equally. Standard
consumer modems purchased at the local electronic superstore
are not designed for use with control systems.This often causes
many users of these modems to experience configuration,
performance and durability problems when used in an
industrial environment.
A better solution is a Rockwell Automation Remote Access
Modem Kit (catalog numbers 9300-RADES and 9300-RADKIT).
Our modem kits are specifically designed to allow remote
access to control systems using a standard dial-up connection.
All modems are DIN-rail mountable and come with the software,
cables and adapters required for quick setup and ease of use.
For more information on Remote Access Modem Kits, go to page
78 or www.rockwellautomation.com/services/rmd/radkit.html

43
Q What are the most common
mistakes made when
implementing condition
monitoring technology?
A As is the case with any new technology, first-time users of
condition-monitoring technology must gain a little experience
with it to realize the greatest return.The following information
can help you avoid three common mistakes.
1. Improper Collection Frequency
Users must match the frequency of acquiring data to failure
modes typically exhibited by the type or class of equipment
being monitored. For example, collecting data every 30 days
will not effectively alert operators of failures that typically
occur within a week.
It is extremely important to apply the right data collection
devices to each class of machine so you can detect failure in
the early stages and allow time for predictive analysis and for
scheduling the required maintenance.
2. Failing to Act upon Data
As important as data collection is to condition monitoring, it
is far more important to actually do something with the data.
Unfortunately, reliability engineers and maintenance technicians
often do what needs to be done now, such as repairing broken
equipment, instead of analyzing data.A variety of analysis
solutions exist, but all involve taking the analysis away from
those who are busy with other tasks. For example, you could
install intelligent condition monitoring technology that can
detect and diagnose developing problems that can lead to
failures, and then send alarms or alerts to appropriate staff.
Another option is to hire an analyst.This person could be a
full-time employee, depending on your requirements.
3. Underuse of Technology
It’s not unusual to invest in technology and use only a small
portion of its features and capabilities.The reasons stem from
improper specification, poor planning, poor implementation
and lack of trained or adequate resources.To avoid this problem,
consult with your local authorized Allen-Bradley distributor or
Rockwell Automation sales specialist to ensure the right level
of technology is specified for the application.You should also
discuss the staffing required to support the technology and
then budget accordingly to provide the proper training.
Q What is the Flying Start feature
of a PowerFlex®
x Variable
Speed Drive?
A The Flying Start feature is used to reconnect the drive to a motor
that is already spinning to quickly resume normal operation with
minimal impact on load or speed. Since the motor is “picked up”
smoothly at its rotating speed and ramped to the proper speed,
little or no mechanical stress is present reducing wear and tear
on the motor. In some large fan applications, wind or drafts may
rotate the fan in the reverse direction when the drive is stopped.
Flying Start will determine speed and directional rotation, then
execute controlled deceleration to zero and reacceleration to the
commanded speed.

44
Q What is the difference between
repair and remanufacturing?
A Many companies providing traditional repair services for
automation equipment only address the issues that are
directly causing equipment malfunction or failure. No other
actions are taken to ensure proper equipment performance.
Remanufacturing services, such as those provided by
Rockwell Automation, not only fix the problem that caused
the malfunction/failure, but restore the equipment to its
original operating condition.The Rockwell Automation
remanufacturing process includes:
Receipt and Verification Catalog numbers, series, and revision
levels are verified.The application of our bar code allows for
easy tracking of repair history and order status.
Revisions and Enhancement Your equipment is cleaned, inspected,
and updated to latest applicable hardware and copyrighted
firmware revisions.This helps extend the life expectancy of your
equipment and permits integration with our newer,
more sophisticated products.
Component Verification/Replacement Rockwell Automationt
utilizes a proactive and preventive maintenance approach to
Remanufacturing services. Suspect components are tested,
verified and replaced with Rockwell Automation specified
quality components if needed.
Damaged components will be replaced by parts that have
been pre-screened, burned-in, and specifically selected for
Rockwell Automation.
Dynamic Functional Testing Specialized experts determine
operational status using dedicated test equipment including
parametric testing.
Environmental Testing All equipment returned for repair
undergoes dynamic environmental testing to identify
intermittent problems not readily apparent, helping
prevent premature failures.
Final Quality Control Inspection All returned equipment is
cosmetically cleaned and visually inspected by quality
control inspectors for complete compliance to
Rockwell Automation standards.
Shipping Equipment is placed in custom-engineered
anti-static bags and containers to help protect them
against static discharge during shipment.
Warranty All remanufactured equipment include a
12-month warranty.
Quality Based on customer surveys, the Rockwell Automation
remanufacturing methodology produces superior results
compared to those used by 3rd party repair vendors. Equipment
repaired by the third-party vendors can result in three times
more warranty failures than equipment remanufactured by
Rockwell Automation.
Q & A
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45
Q Does RSMACC™
Change
Management software
comply with the FDA’s 21
CFR Part 11 regulation?
A Meeting 21 CFR Part 11 compliance regulations involves
more than software.While software can enable compliance
of a facility, the ongoing ability to manage electronic records is
what allows a company to meet the regulations. Compliance
requires technical product-based solutions, as well as
manufacturer policies and procedures.The manufacturer is
ultimately responsible for validating, and maintaining the
validation of, the manufacturing process.
Q Is the RSMACC Archive
function a document
management system?
A Archive is a source code manager. It is not a document
management system.While Archive can be used to store any
file used in your facility, it does not contain features commonly
found in document management systems such as workflow,
electronic approvals, and configurable revision number formats.
Q Does RSMACC require
database experience?
A No. RSMACC installs everything you need to get up and running.
The installation process creates all databases, tables, and views
required to deploy your system. Simply follow the installation
instructions and you are ready to go.
Q Does Emonitor®
r software
integrate with other Rockwell
Software systems?
A Yes, it does. Emonitor publishes information about analyses and
other events to FTDiagnostics. These events can be viewed and
acted upon by the RSMACC suite of products.
Q Is there any way to prevent
unauthorized personnel from
accessing my Ethernet control
network and making changes
to the control programs?
A Yes.The Rockwell Automation Ethernet Diagnostics Module can
also be used for this function.The module identifies any attempt
to access the network by an unauthorized user and notifies the
control system.The unauthorized user is denied access to the
network to prevent unnecessary or unintended changes.

46
Q What are the data sources for
Emonitor?
A XM modules - this family of devices sits on a DeviceNet
network and produces vibration, temperature, position, speed,
and other types of data.The entire family of XM devices can
feed data into the Emonitor database.
Enwatch®
online surveillance monitoring hardware - this is
a family of 16 channel or 8 paired channel Ethernet enabled
surveillance devices. Currently supported are the Enwatch and
the Enwatch PX.These devices can be used to gather vibration,
temperature, humidity, pressure, and other signals for inclusion
into your condition monitoring program.
Hand held data collectors - Rockwell Automation offers a series
of hand-held vibration meters that can be used for manual data
collection.These meters load their collected data into Emonitor.
FactoryTalk®
LiveData and OPC data - with this capability
any process data from a valid server can be loaded into the
Emonitor database.
Q & A
Q What is a ‘tag’ as
defined by Emonitor?
A A tag is a measurement that a sensor collects. Each sensor can
have more than one measurement (tag) associated with it.
Q What database engines does
Emonitor support?
A For the Workstation applications (catalog numbers 9309-
ODBS000ENE & 9309-ODBS500ENE), the database engine
is a single user Centura engine developed by Gupta, Inc.
For the networking applications (catalog numbers
9309-ENSH000ENF, 9309-ENSH500ENF, 9309-ODDX000ENF &
9309-ODDX500ENF), the database engine is either Microsoft’s
SQL Server, Oracle or Gupta’s multi-user engine.
Q How does Emonitor software
“predict” machine failures?
A Over time, a machine’s condition can change.This change can
be associated with mechanical changes in the machine, or
other issues. Emonitor specializes in identifying the mechanical
issues that indicate machinery degradation. By analyzing this
trend data, and coupling that with frequency based analysis
of vibration spectral data, machines that are degrading can be
identified.The appropriate corrective maintenance can then be
scheduled to address the problem before it causes a serious loss
of production.
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47
Q How does FactoryTalk®
kk
Security work with
FactoryTalk Directory?
A FactoryTalk®
Security authenticates the identities of users and
authorizes user requests to access a FactoryTalk-enabled system
against a set of defined user accounts and access privileges held
in the FactoryTalk Directory™
. FactoryTalk Security provides
security services integrated into both the FactoryTalk Local
Directory and the FactoryTalk Network Directory.
FactoryTalk Directory references tags, data servers, security
settings, and other project information from multiple data
sources, and then makes this information available through
a lookup service to all software products participating in an
automation system.
For example, tags are stored in their original native
environments, such as logic controllers, and graphic displays
are stored in the HMI servers where they are created.Yet all
of this information is available, without duplication, to any
participating FactoryTalk-enabled product in a system.
The FactoryTalk Automation Platform includes two separate
directories: a Local Directory and a Network Directory. In
a FactoryTalk Local Directory, all project information and
all participating software products are located on a single
computer, and the FactoryTalk-enabled system cannot be
shared across a network or accessed remotely.
A FactoryTalk Network Directory organizes project information
from multiple software products across multiple computers on
a network. Even if a Local Directory and a Network Directory
are configured on the same computer, all of their project
information and security settings remain completely separate
and cannot be shared.
Depending on the software products you install on your
computer, you might need to use only the Network Directory,
only the Local Directory, or both.Which directory you need
depends on the software products you plan to use, and whether
you plan to work in a stand-alone or a networked environment.
For example, if you use RSView®
SE Distributed or RSSql™
,
you will use the Network Directory. If you use RSView®
ME
or RSView SE Station, you will use the Local Directory. Other
products, such as RSLogix™
5, RSLogix™
500, and RSLinx®
Enterprise, allow you to use either directory. Consult your
product documentation for details.

48
Q How does FactoryTalk Security
get policies for new products
that are added to the system?
A New Product Policies are installed to the FactoryTalk Directory
during the new product install process. In addition, the
FactoryTalk Directory installs with a few of the most current
Product Policies in order to simplify and expedite the
install process.
Q & A
Q How does FactoryTalk Security
secure access to specific devices
in my facility?
A FactoryTalk Security uses network-relative paths to identify
control networks and devices.A network-relative path uses
a network as the starting point and ends with the target
network or device.The name of the network corresponds
to the RSLinx®
Classic driver name.
To share security information for networks and devices,
you must use common RSLinx Classic driver names to refer
to shared networks. If two computers use different driver
names to identify the same control network, each computer
has separate security information, even if the information is
for the same networks and devices. Similarly, two computers
that reach the same physical network with different
communications paths also have separate security information
for the same network.
Some products, such as RSLogix 5000, do not use network-
relative paths for identification, but refer to control hardware
security information using a logical device name. In this case,
the logical name allows a ControlLogix®
device (regardless of
path) to always use the same security information.To allow
other types of devices to be identified by logical name rather
than by path, FactoryTalk Security gives you the option of
creating logical names (sometimes called aliases) for devices
instead of using network-relative paths.
Q I am in the concept phase of
a new automation project.
Why do I need to worry about
maintenance now?
A Determining your maintenance strategy early in the project life
cycle will ensure the right predictive, preventive and reactive
approaches (and technologies and resources to support them
- such as condition monitoring and training) are included in
the design requirements so you can meet your goals for the
project. Identifying and implementing the right maintenance
approaches from the beginning will help you maximize system
performance, extend equipment life, and reduce total cost of
ownership. New or alternative maintenance approaches can
be introduced later in the project life cycle but often come
with higher implementation costs, not to mention the negative
impact on performance, equipment life, and cost of ownership
incurred during the time less effective maintenance methods
were employed.
For help identifying the right maintenance strategy for your new
automation project, contact your local Rockwell Automation
sales office or authorized Allen-Bradley distributor.

49
Q Do I need to purchase
FactoryTalk Security activations?
A This depends on whether you plan to use the new FactoryTalk
Security services and whether you plan to use a FactoryTalk
Local Directory or a FactoryTalk Network Directory.
• If you use a Local Directory to create and manage Local
applications on a stand-alone computer, you do not need
FactoryTalk Security activations.
• If you use a Network Directory to manage centralized
security for network applications across multiple
computers on a network, you are free to create 10 or
fewer user accounts without purchasing FactoryTalk
Security activations. If more than 10 users need access
to your automation system, then you need to purchase
FactoryTalk Security activations for each of those
additional user accounts.
Once the limit of 10 user accounts is reached, you need one
FactoryTalk Security activation for each additional user account
you want to create in a FactoryTalk Network Directory.
For example, suppose you want to allow 35 different user
accounts access to your FactoryTalk-enabled system that
is distributed across a network.After creating the first 10
user accounts, you would need to purchase an additional 25
FactoryTalk Security activations. If later you wanted to add
10 more user accounts, you would simply purchase 10 more
FactoryTalk Security activations.
If your security policy allows, you can create a “guest account”
and have multiple people log in as “Guest.”This “guest account”
requires a single activation.This is not recommended,
because there is no way to trace an error back to the user
who caused it.
You can also link existing Windows®
user accounts and
Windows groups into FactoryTalk Security. In this case,
you need one FactoryTalk Security activation for each
Windows-linked account you want to use in the
Network Directory.

50
You have access to a wide
variety of Rockwell Automation
eTools that can help you
maintain your automation
assets. From product &
services selection tools to
online support requests
to downloads of software
updates, you can get the
resources you need to plan
and execute a successful
maintenance strategy.*
*Some eTools may require
services or support purchase.
Remanufacturing, Repair and
Exchange Parts Search
With this powerful search tool, you can obtain detailed
Remanufacturing, Repair and Exchange Parts information,
including pricing, for over 100,000 products. Once registered,
you can view up to date information on any existing repair
or exchange orders you have placed with us. To access the
search tool, go to:
http://apps.rockwellautomation.com/apps/reman/remanLogin.racs

51
Product Selection Toolbox
The Product Selection Toolbox offers a powerful range of product selection and
system configuration tools to help you choose and apply Rockwell Automation
products, services and support. To download the Product Selection Toolbox, or
order it on DVD, go to www.ab.com/pst.
The Product Selection Toolbox includes the following applications:
ProposalWorks provides access to information on a
broad range of Allen-Bradley products and services, such
as XM Intelligent I/O Machinery Protection (below).
It provides an easy to use product selection interface to
make it a snap to determine the exact catalog number
for the item you need and to access current list pricing.
Once you have selected the appropriate product
the software automatically selects the appropriate
informational documents, photos, etc. for that product
and provides you the ability to include them in a
request for quote document.
In addition to ProposalWorks, the Product Selection
Toolbox also includes:
Programmable Controller Family Selector helps you pick the
right programmable controller based on your currently
installed products and I/O and network requirements.
CrossWorks™
is an online tool that helps you convert
competitive product catalog numbers to similar
Allen-Bradley products.
Industrial Computer Family Selector helps select the right
industrial computer or monitor for your application;
Operator Interface Selection Tool helps choose the right
operator interface for your application.
Distributed I/O Family Selector helps select the appropriate
I/O by displaying I/O families that meet your requirements.
Integrated Architecture Builder is the premier software for
configuring logix-based systems because it helps specify
and generate bills of materials for NetLinx-based networks
like DeviceNet, ControlNet and EtherNet/IP and define
automation system components quickly.
CenterONE®
is an intuitive software application designed
specifically for configuring Motor Control Centers,
reducing user error and design time.
MCS Star provides assistance in configuring MCS starters
for rated motor voltages from 230V up to 690V as well as
complete mounting system assemblies.
MotionAnalyzer helps you select the correct motor for your
application, the proper drive, and a gearbox (if required)
and has effective optimization capabilities to get the most
out of the selected motor and drive combination.
Restore and Backup allows you to save and restore complex
DIN-Rails and any other critical program data.
Support Case Management
Our interactive case management Web site
is available for TechConnect Enterprise and
PriorityConnect customers. This comprehensive
tool allows you to manage your support issues
and review the case activity at your site. You
can view, edit, add notes to and close existing
support cases and create new support cases
(for your location). Existing cases can be easily
located with a built-in query function.

52
MySupport Electronic Notification System
http://support.rockwellautomation.com/MySupport.asp
The MySupport Electronic Notification
System gives you the ability to personalize
the Rockwell Automation Services & Support
Web site for your specific product interests.
MySupport can send you regular e-mail
notifications with links to new technotes,
software updates, and firmware updates for
those products. A notification window displays
the same information on Services & Support
Web pages when you log in.
To learn more about MySupport,
or become a registered user, go to
http://support.rockwellautomation.com/MySupport.asp
Online Support Requests
http://support.rockwellautomation.com/supportrequests/
When you have a non-critical technical issue, you can
submit an online support request for many Rockwell
Automation products. To submit a request, go to
http://support.rockwellautomation.com/supportrequests/
and follow the on screen instructions. Your request
will be routed to an automation specialist with the
appropriate product and technical knowledge to resolve
your issue. In most cases, you will receive an e-mail
response to your request from our specialist within 24
business hours.
* Support purchase is required to submit online support
requests for some products. Some support programs
may utilize an alternate method of submitting requests.

53
eTOOLS
The Rockwell Automation knowledgebase
(http://support.rockwellautomation.com/)
knowledgebase is your 24x7 online source
for support related information about
Allen-Bradley, Rockwell Software, and Reliance
Electric products. Knowledgebase content
includes application notes, error messages,
problems/solutions and release notes.
You can find information in the
knowledgebase using three different search
methods. To quickly search for all tech notes
published within the last 30 days, click on
search method 1 and click find. To search
for a specific product or topic, click on
search method 2 and enter a keyword(s) or
use the drop down boxes to enter a product
group, product family and/or topic. The drop
downs can be used with a keyword for the
most targeted search. Finally to search for a
previously viewed document, enter the Tech
note ID# in the box provided and click find.
Additional information on using the
knowledgebase can be found online.
Rockwell Automation Knowledgebase
http://support.rockwellautomation.com/knowledgebase

54
Online File Downloads
http://support.rockwellautomation.com
A wide variety of update and utility files are available
for download 24x7 via the Internet. With our online
downloads, you can easily find and obtain the files you
need, when you need them. No need to wait for a CD
or DVD to arrive in the mail.
To use our online downloads, simply go to
http://support.rockwellautomation.com/ and select/
the desired file type under Downloads on the left
navigation bar. Available file types include:
• EDS files
• Reset Codes
• Firmware Updates
• Software Updates
• Add-on Profiles
• Miscellaneous Utilities and Downloads
Support purchase is required to download
some file types.
Controls & Networks Certification Pretests
Determine whether you are ready to take the Rockwell Automation
Controls and Networks Certification online exam or have the
prerequisite knowledge to attend our certification preparatory
course, Controls & Networks System-Level Integration. By taking
the online Controls and Networks pre-tests at our Web site, you
can make a better decision about your readiness level for either one
of these certification track events. Try the free pre-tests by visiting
http://www.rockwellautomation.com/services/training/access.html

55
eTOOLS
Instructor-led Training Course
Schedules and Selection Tool
When you want to know where and when Instructor-led
courses are scheduled throughout the United States, use our
online search to find it quickly. Links to course descriptions,
knowledge tests, and enrollment information can be found at
http://www.rockwellautomation.com/services/training/schedules.html
or click on the Training Schedules link under the Resources
heading in the upper right Rockwell Automation Training
Services Web pages.
Not sure about the right course to take? You can assess your current
knowledge of course content by taking a free, online assessment
that addresses some of the topics in a specific course. Our Course
Selection Tool includes short, online product knowledge tests including
your real-time test score and recommendations for improvement.
The results can help you determine in advance if a course will meet
your learning goals. To view the list of free self-assessments,
visit http://www.rockwellautomation.com/services/training/tool.html.
Training Voucher Account Management
This tool is designed for participants in the Rockwell Automation
Training Voucher Account savings program. You can check
your voucher account balances quickly by visiting
http://www.rockwellautomation.com/services/training/voucher.html

56
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maintenance
products,
services
& support
Rockwell Automation, the industry leader in control
and automation, is uniquely qualified to help
you meet your production and business goals
through strategic maintenance. From our integrated
product architecture to our global network of
spare parts hubs, field support engineers, and
phone support, repair and training centers,
we can provide the technology and predictive,
preventive and reactive resources you need to
reduce downtime, operate
equipment to specifications,
and improve speed to change.
When your maintenance strategy focuses on
these issues you will optimize the performance
and utilization of your automation assets and
improve your top and bottom line.
For more information on our maintenance-related
products, services and support, view the following
pages. Each section includes the following predict,
prevent, react symbol.
This symbol indicates which maintenance approach(s)
is supported by that product or service. In the
example above, both a predictive and preventive
approach are supported. Match the symbol to the
desired maintenance approach in each area of
your production environment on your maintenance
map (page 21) to identify the appropriate products
and services for that approach. For example, if a
predictive and preventive approach are desired,
a condition monitoring system and network services
may be appropriate to meet your needs.
Identifying the right maintenance approach for each
production area, and the products and services
to support that approach, are critical to achieving
your production and business goals through
strategic maintenance. To help you determine the
maintenance strategy that will best meet your needs,
contact your local Rockwell Automation sales office
or authorized Allen-Bradley distributor.
predict prevent react
57
Pd Pv Re
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Identify the personnel and equipment issues
that hinder your production performance
and develop a maintenance strategy that
will maximize your overall equipment
effectiveness and return on net assets
assessment services
Integrated Performance
Assessment Services
Integrated Performance Assessment Services
evaluate the ability of your plant personnel
to consistently perform at the desired level by
examining key success factors such as:
• Motivation/Incentive Systems
• Physical Work Environment
• Skills and Knowledge
• Performance Support
• Processes & Procedures
• Automation Products and
Supporting Technologies
Installed Base
Evaluation™
Services
Spare parts represent a significant cost for manyfi
users of automation technology. One of the firstfi
steps in reducing spare costs is an evaluation of
your automation equipment installed base and
are parts inventory. The evaluation considers
ow equipment is used in your applications and
nvironment. This includes how your company is
anaging its MRO inventory, maintenance
story, as well as repair and maintenance
ocedures. After the Installed Base Evaluation™
,
ou will receive a comprehensive analysis that
entifies equipment locations and status offi
are parts including:
Active - Critical spares and spares you may need
Excess - Overstocked spares
Inactive - Spares for old or obsolete equipment
is analysis can help you make informed
ecisions about inventory levels, procedures,
nd costs without sacrificing uptime.fi
With Rockwell Automation Assessment Services, you
can identify the people, process, and equipment issues
that are hindering your production performance in every
aspect of your plant operations. From manufacturing
automation to information solutions, our consultants
have the hands-on manufacturing experience and
technological knowledge to provide you with more than
just recommendations – you’ll receive comprehensive,
objective information about problem areas that are
reducing your efficiency and increasing your costs.fi
Our Assessment Services don’t stop with just problem
identification. Unlike many consulting fifi rms, our automa-fi
tion specialists will help you resolve those problems.
In addition to problem identification, you will receivefi
a complete in-person review detailing the appropriate
maintenance approach, and the resources required to
execute it, for your operations. When executed, by your
maintenance organization or with the help of Rockwell
Automation®
Services & Support, the maintenance
strategy will optimize the performance and utilization
of your automation assets to meet your production and
business goals.
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AssessmentServices
Plant Baseline Evaluation™
Services
With Plant Baseline Evaluation™
Services from Rockwell
Automation, our experienced technicians gather performance
data from your new or existing programmable controllers, drives
and related peripheral devices and analyze it relative to optimum
operating conditions.
A Plant Baseline Evaluation may include the following activities:
• Identify and check all items on the evaluation list
• Evaluate all AC, DC, tachometer, resolver and other devices
mounted external to the drive cabinet
• Measure and record all pertinent oscilloscope signals for each
drive in the system
The evaluation helps you identify existing and potential equipment
problems and determine the appropriate corrective actions to
improve equipment performance and minimize/prevent unplanned
downtime. The evaluation also provides a baseline which future
maintenance checks can be measured against to ensure continued
performance to specifications.fi
Reliability Program Assessment Services
Rockwell Automation reliability specialists can help you develop
the Condition-based Maintenance (CbM) program that will meet
your defined goals and objectives. Through a Reliability Programfi
Assessment, you will receive valuable information that will
ensure the success of your new or existing CbM program:
• The program is efficient from the startfi
• The program is designed to only include those functions that
bring significant returnfi
• Cost justification is obtained before signififi cant funds are spentfi
• Performance metrics are established to measure success
throughout the life of the program
• Cultural issues that may inhibit success are identifiedfi
and a remediation plan is developed
Network Evaluation Services
Our Network Evaluation Services include Baseline and Annual
Performance Evaluations, Network Health Checks, Network
Validation, and Network Troubleshooting and Repair. See the
Network & Security Services section for more information.
Controls Security Assessment Services
The Controls Security Assessment is designed as a key first step infi
an overall security deployment plan. See the Network & Security
Services section for more information.
All Rockwell Automation
Assessment Services include
complete documentation of tasks
performed and recommendations
for improvement (excerpt from an
Integrated Performance Assessment
summary report shown).
For more information about all Rockwell Automation Assessment Services,
go to www.rockwellautomation.com/services/assessment/index.html
59
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The following pages will take you through the steps for
selecting a continuous monitoring and protection system.
Here is what you’ll need:
Required
Measurement Module
Terminal Base
Sensor
Sensor Mounting
Cables
Power Supply
Optional Modules
Terminal Base for
optional modules
Enclosure
Junction Box
Switch Box
Communications
Graphic Terminal
Software
Services
Support
Training
Optional
Your path to improved machine
productivity and reduced costs
conditionmonitoring
systems
Condition Monitoring, as part of a Condition based Maintenance Program, provides critical information
about the condition of your mechanical assets to predict potential problems/failures. This information
will help you optimize the scheduling of downtime, labor, and materials for required maintenance.
The Allen-Bradley®
XM®
series of intelligent I/O modules process in real-time the critical parameters used
in assessing the current health, and predicting the future health of industrial machinery – also providing
machinery protection where needed.
The XM series is a family of DIN rail mounted measurement, relay and communications modules that
can be deployed as necessary to service almost any monitoring or protection application. XM series
modules may be applied as a standalone system, or they can be integrated with existing automation
and control systems, including programmable controllers and displays.
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For an easy to install vibration monitoring solution that includes
measurement module, relays, display and status indication
If selecting a packaged product
Packaged Products:
❑ XM-720 w/XM-120 Standard Dynamic
1440-PK02-05M0
❑ XM-720 w/XM-121 Low Frequency
1440-PK02-05M1
❑ XM-720 w/122 g’SE
1440-PK02-05M2
Move to Steps 3 – 5
For general purpose monitoring for shaft, casing or pedestal
vibration in rotating equipment including turbines, motors, pumps,
compressors, fans and most other common rotating equipment
Dynamic Measurement Module:
❑ XM-120 1440-VST02-01RA
For general purpose monitoring with high pass filter for
measurements as low as 0.2Hz (12CPM). For monitoring
machinery such as hydro turbines and many fans, gearboxes,
paper rolls extruder presses and other low speed equipment
Low Frequency Measurement Module:
❑ XM-121 1440-VLF02-01RA
For the ability to measure g’SE overall and gSE spectra
measurements ideal for monitoring motors, pumps, fans
gearboxes that are fitted with rolling element bearings
Vibration Module:
❑ XM-122 1440-VSE02-01RA
For monitoring aeroderivative and industrial gas turbines
Aeroderivative Module:
❑ XM-123 1440-VAD02-01RA
For monitoring overall (direct) vibration levels
Overall Vibration Modules:
❑ XM-160 1440-VDRS06-00RH
(with accelerometers)
❑ XM-161 1440-VDR06-06RH
(with 4-20mA Outputs)
❑ XM-162 1440-VDRP06-00RH
(with Non contact Pickup Power)
Serial Communication Cable
(one cable is required per customer site)
XM Serial Communication Cable
❑ 1440-SCDB9FXM2
Measurement Module(s)1
ConditionMonitoring
Required
For more information, go to
www.rockwellautomation.com/
services/conditionmonitoring/
61
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62
CONDITION
MONITORING
(Required)
Required
General Purpose Accelerometers
(100mV/g):
❑ 9300 Top Exit EK-43792I
❑ 9200 Side Exit EK-47086I
Low Frequency Accelerometer:
❑ EK-43794I 9100L with Top Exit (500 mV/g
High Frequency Accelerometer:
❑ 9700A with 10-32 Side Exit (10 mV/g)
EK-43799I
For Hazardous Locations:
❑ 9100FM Top Exit with FM Certification
EK-43785I
❑ 9100CSA Top Exit with CSA Certification
EK-43786I
❑ 9200FM Low Profile with FM Certification
EK-43789I
❑ 9200CSA Low Profile with CSA Certification
EK-43790I
Sensor(s)3
Terminal Base(s)
Each XM module must have a terminal base
2
From step 1, If you chose: Select terminal base:
XM-120 ❑ 1440-TB-A
XM-121 ❑ 1440-TB-A
XM-122 ❑ 1440-TB-A
XM-123 ❑ 1440-TB-A
XM-160 ❑ 1440-TB-H
XM-161 ❑ 1440-TB-H
XM-162 ❑ 1440-TB-H
Sensor Mounting4
❑ Mounting base for epoxy mounting with stud 1/4-28” and epoxy kit for 2 mounting pads
EK-44156 and EK-44801
❑ Spotface Tool EK-42053
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63
Splash Proof Cables for
2-Pin Sensor for Models:
2-socket Connector to Blunt Cut; Twisted-shielded pair;
Teflon Jacket:
❑ 16ft Assembly EK-46800I
Cost Effective Cables for
2-Pin Sensors for Models:
2-socket Molded Connector to Blunt Cut; Twisted-shielded pair;
Teflon Jacket:
❑ 16ft Assembly EK-44134
Cables5
ConditionMonitoring
Required
Power Supplies6
24VDC Power Supply:
❑ 1606-XLP-30E 1.3A
❑ 1606-XLP-50-E 2.1A
❑ 1606-XLP-100E 4.0A
For measuring speed, rotor acceleration and peak speed
Dual Speed Module:
❑ XM-220 1440-SPD02-01RB
For measuring all common turbine supervisory position
measurements including axial position (thrust), valve position,
differential expansion and case expansion
Position Module:
❑ XM-320 1440-TPS-02-1RB
For measuring DC voltage or loop current
Process Module:
❑ XM-360 1440-TPR06-00RE
For measuring either an RTD or an isolated thermocouple
Universal Temperature Module:
❑ XM-361 1440-TUN06-00RE
For measuring isolated or grounded thermocouples
Thermocouple Temperature Module:
❑ XM-362 1440-TTC06-00RE
For master capabilities to provide remote, shared and
voted relay operation
Master Relay Module:
❑ XM-440 1440-RMA00-04RC
For expansion relay, adding 4 additional relays to
any XM measurement or XM master relay module
Expansion Relay Module:
❑ XM-441 1440-REX00-04RD
High performance voted relay solution for
Electronic Overspeed Detection System
Voted EODS Relay Module:
❑ XM-442 1440-REX03-04RG
Optional Module(s)7
Optional
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64
CONDITION
MONITORING
(Optional)
Optional
❑ ASM, NEMA 4, 20 terminals EK-32620
❑ NEMA 4X Fiberglass, 12 terminals EK-NS31414
Junction Boxes10
❑ DeviceNet to Ethernet Gateway 1440-GWEN2DN
(For Emonitor and RSMACC connectivity)
❑ Ethernet/IP to DeviceNet Linking Device 1788-EN2DN
(For integration with PLCs and HMI)
Communications12
Switch Boxes11
Nema 4X, (1) BNC Sensor Output,
Cable Grip, Composite Material:
❑ 2-Channel Termination Box EK-45077
❑ 4-Channel Termination Box EK-44391
Nema 4X, (1) BNC Sensor Output &
(1) BNC Tach Output:
❑ 6-Channel Switchbox, Stainless Steel EK-44167
❑ 12-Channel Switchbox, Composite Box EK-45079
Terminal Base(s) for optional modules
Each XM module must have a terminal base
8
From step 1, If you chose: Select terminal base:
XM-220, XM-320 ❑ 1440-TB-B
XM-360, XM-361, XM-362 ❑ 1440-TB-E
XM-440 ❑ 1440-TB-C
XM-441 ❑ 1440-TB-D
XM-442 ❑ 1440-TB-G
XM Enclosure 4 Position:
❑ NEMA 4X w/Window 1440-E4P460N4XW
❑ NEMA 12 w/Window 1440-E6P600N12W
❑ NEMA 4 1440-E6P600N4
❑ NEMA 4X 1440-E6P600N4X
❑ NEMA 4X 1440-E8P770N4X
❑ NEMA 4 1440-E8P770N4
❑ XM NEMA 4 1440-E9P925N4
❑ XM NEMA 4X 1440-E9P925N4X
❑ XM NEMA 4X w/Window 1440-E9P925N4XW
Enclosures9
Note: Power supplies count as 2 positions.
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65
ConditionMonitoring
Optional
Graphic Terminals
XM Continuous Online Monitoring and Protection System integrates with standard Allen-Bradley visualization products, such as
PanelView™ and VersaView displays. The product family spans not only different size displays, but monochrome and color options
along with touch screen and keypad for operator input. Contact your local Rockwell Automation Sales Representative for help
selecting just the right display to meet your applications specific requirements.
13
Emonitor
(see page 66 for description)
Emonitor Enterprise Bundle (multiple sites):
❑ 9309-ENSH500ENF with 500 tags
❑ 9309-ENSH000ENF with unlimited tags
Emonitor Factory Bundle (multiple users):
❑ 9309-ODDX500ENF with 500 tags
❑ 9309-ODDX000ENF with unlimited tags
Emonitor Workstation Bundle (single user):
❑ 9309-ODBS500ENE with 500 tags
❑ 9309-ODBS000ENE with unlimited tags
RSMACC Enterprise Online
(see page 70 for description)
RSMACC Enterprise Online Condition Monitor:
❑ 9515-RSEOL016ENE, 16 XM
❑ 9515-RSEOL000ENE, Unlimited XM
Software14
Services
If you are installing a new online condition monitoring system, or refurbishing an existing one, Project Services provides the expertise
needed to ensure your success. From setting up and commissioning standalone online monitoring to complete installation of large,
complex monitoring solutions, you’ll receive experience that has proven to be invaluable to customers worldwide.
❑ System Commissioning, Configuration and On the Job Training 1443-S-XM
❑ Multi-user Software Installation, Set-up, and Configuration 1443-P-MUP
15
TechConnect
SM
Support - 24x7x365
❑ DirectConnectSM
9800DC24AUTOA
❑ PriorityConnectSM
9800PC24AUTOA
16 Training
❑ Introduction to Vibration Technology EK-ICM101
❑ XM fundamentals EK-ICM165
❑ Emonitor Enshare Basic EK-ICM141
17
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66
Today’s globally competitive economy has resulted in
signiﬁcant shifts in the relationships between producers,ﬁ
suppliers, and consumers. The need for improved
production reliability and reduced expenses is clearly
demonstrated by production strategies such as “just-in-
time” material supply and delivery.
As a manufacturer, to be successful in this environment,
it is vital you optimize your investment in critical
production assets. Simply put, to ensure future growth
you must maximize your Return on Net Assets
[RONA = (Plant Revenue-Costs) / Net Assets].
The Emonitor®
family of products provides you with
a suite of integrated maintenance data functions to
leverage information about your assets. This enables
you to make intelligent, informed decisions that
maximize uptime, reduce inventory, cut production and
maintenance costs, and improve your Overall Equipment
Effectiveness [OEE = Availability x Rate x Quality].
Emonitor software specializes in the analysis and
storage of vibration data. Emonitor can easily diagnose
problems such as bearing wear and unbalance with
its built-in analysis capabilities. Emonitor allows the
vibration analyst to easily diagnose and remedy
complex issues on equipment.
Complete storage and
analysis of vibration data
®
software
Emonitor Plant Wide Asset
Data Integration Functions:
• Asset Register
• Condition Monitoring Capabilities
• Asset Health Analysis/Intelligent Advisory
• Operations and Maintenance Advisories
• Web Client Access
For more information, go to
services/conditionmonitoring/
emonitor.html
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67
ConditionMonitoring
Predictive maintenance
services for maximizing the
reliability of your plant
condition
monitoringservices
Reliability Services
With Reliability Services from Rockwell Automation,
you can optimize your Condition-based
Maintenance (CbM) program by identifying problem
areas, implementing necessary changes, and
measuring program performance for continuous
improvement.
To identify problem areas, Rockwell Automation
conducts a reliability audit to benchmark Key
Performance Indicators (KPI) and create a strategic
maintenance plan that optimizes your CbM
program. Rockwell Automation reliability specialists
can then help you implement and manage the CbM
program to assure defined goals and objectives arefi
achieved.
Contract Services
When you need to turn condition monitoring data
into actionable Condition-based Maintenance
information, Rockwell Automation can provide the
certified resources for analysis of vibration, infraredfi
thermography, oil and other condition monitoring
technologies. Services include data collection,
analysis, program management and online
reporting tools.
Project Services
If you are installing a new online condition
monitoring system, or refurbishing an existing one,
Rockwell Automation can help you from start to
finish. From setup and commissioning for standalonefi
online monitoring to complete installation of large,
complex monitoring solutions, you will obtain the
skilled resources to ensure successful implementation
of your project - from planning and design through
installation, testing and operation.
Callout Services
Do you occasionally need a fan balanced,
Infrared Thermography performed or a critical oil
analysis completed to supplement your existing
CbM program? Or, do you have a reliability
problem that just can’t be solved? Our condition
monitoring specialists are available on a callout
basis to give you the help you need, when you
need it.
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68
assetmanagement
services
Optimize your MRO process and spare parts inventory
Maximize the return on your automation assets with MRO process and spare parts management.
Proactively managing the costs of your spare parts can reduce unplanned downtime, extend
your equipment life, and minimize repair and carrying costs – increasing your Return On Net
Assets (RONA) and Overall Equipment Efficiency (OEE).fi
Your Asset Management
Professional will provide:
Warranty tracking to identify if failed
equipment is under warranty
• Asset tracking using bar code and
RFID technology
• Consolidated asset reports (warranty and
asset tracking, repair spend and ROI)
Your Asset Managment Professional
will also help you:
• Manage Obsolescence
• Identify Opportunities For Standardization
• Flag Common Mode Failures
• Provide Accurate Data to Improve
Maintenance Decisions
RAAMP™
- MRO Process Management
Excess spares, unmanaged storerooms, and inefficient MRO processes make it a challenge to establishfi
a stable production environment and maintenance budget. To help you improve your MRO process
management, Rockwell Automation offers RAAMP - a unique
predictive service that provides a proven repair methodology for
your automation assets. The methodology, which is implemented
by an on-site Asset Management Professional (AMP), will
optimize your spare parts inventory and simplify your repair
transactions. RAAMP includes a one year in-service warranty
on repaired equipment.
Results
ReturnOnNetAssets With
RAAMP
Without
RAAMP
Decrease Your
Costs
Optimize
Assets
Improve Your
Plant
Productivity
• MRO Process Assessment
• Reliability Based Reporting
• Asset Management Professional
Optimize your assets
• Installed Base Evaluation
• Asset Tracking
• Continual Assessment
Decrease your costs
• Centralized Repair Services
• Warranty Tracking
RAAMP Benefits
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69
AssetManagement
Expenses
With a Parts
Management
Agreement
Without a Parts
Management
Agreement
Space, Utilities,
Equipment
People Benefits
Spoilage/
Obsolescence
Accounting,
Insurance,
and Taxes
Opportunity Cost
Spare Parts Management
A Parts Management Agreement provides
quick access to the Rockwell Automation®
spare parts you need, while reducing your
operating costs to maintain and manage
your spare parts inventory.
Through a Parts Management Agreement,
Rockwell Automation owns and manages
your spare parts inventory for a fixedfi
monthly or quarterly cost. These agreements
are backed by Rockwell Automation’s
remanufacturing and renewal parts
services to replenish any inventory used.
A Parts Management Agreement will
provide you numerous benefits, includingfi
improved asset control (by avoiding
unnecessary inventory build-up) and cash
management (by eliminating large capital
expenditures for spare parts, providing a
fixed agreement payment schedule, andfi
minimizing carry costs).
Parts Management Savings
For more information, go to:
www.rockwellautomation.com/services/assetmanagement
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70
Proactively manage your
asset configurations
RSMACC
™
software
RSMACC™ Change Management software is a
robust set of tools to proactively manage your
manufacturing configuration:fi
• By ensuring that the correct manufacturing
configuration is being used to maximize uptimefi
• By reducing variations in product quality by limiting
access to control devices and controlling actions that
individuals with access rights may perform
• By automatically generating an audit trail of users’
actions as they alter the manufacturing configurationfi
to increase security and accountability
RSMACC Change Management capabilities include:
Access Control/Authentication allows you to control an individual’s access to devices on
your plant floor, the location from which they access the device, and the actions they can perform onfl
the device. For instance, you can restrict an operator’s ability to download a new PLC program.
Archive allows you to restrict and record file usage anywhere in your system. This capability alsofi
protects intellectual property and manages validated programs by requiring users to check files in andfi
out. Archive also maintains version histories by tracking changes made to any file, from PLC programsfi
and graphics, to system documentation reports, and more.
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71
AssetManagement
Auditt
device configurations showing when the changefi
occurred, indisputable evidence of who performed
the change, and the details of the change. Audit is
designed to help keep production on track, while
also providing the data and assurance you need to
remain in compliance with essential quality systems
and regulations.
www.rockwellautomation.com/rockwellsoftware/assetmgmt/rsmacc/index.html
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Reports stored on the RSMACC Server provide consistent views into the RSMACC
Change Management repositories that meet your standards and reporting requirements time
after time from any RSMACC Client in your facility. For example, using RSMACC reporting,
you can view a list of the events occurring in your system during the last eight hours.
Verification allows you to develop schedules to
automatically perform routine operations, such as PLC
program backup and recovery. It also validates that
the device configurations running in your facility havefi
not been unexpectedly changed by comparing them
to archived master versions. Since you schedule these
operations to occur at specific times, you can createfi
custom notifications to handle any situation, forfi
example, you can email an engineer if a difference
is detected. Built-in driver support is realized
for Allen-Bradley®
ControlLogix®
, FlexLogix™
,
CompactLogix™
, PLC-5®
, SLC™
500, MicroLogix™
,
PLC-2®
, and PLC-3®
controllers, Rockwell Automation
drives, PanelView™ Standard on any Allen-Bradley
control network, Enhanced PanelView through RIO
connections, and any file or directory accessiblefi
across your network.
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Real-time troubleshooting and monitoring
of automation equipment and systems by
off-site automation specialists
TechConnectSM
Support
With TechConnectSM
Support, your
site has unlimited access to Rockwell
Automation’s global network of
award winning Customer Support Centers and
technical resources. Whether you need help installing,
configuring and maintaining equipment and software,fi
obtaining software updates, diagnosing and fixingfi
operating problems, or performing basic programming
tasks, we deliver the tools and answers you
need to get and keep your operation up
and running.
Because companies have different
support needs based on the number of shifts
they run, the staffing on those shifts, and the typefi
of equipment/process, TechConnect offers you the
flexibility to choose from three support levels to bestfl
supplement your available technical resources and
goals:
PriorityConnect SM
Priority phone support (unlimited
number of cases), exclusive online case management
tools, proactive case handling/follow-up services and
all the features and options of DirectConnect.
DirectConnect SM
Real-time phone support (unlimited
cases), the latest software updates (for each software
license covered; Web downloadable 24x7x365,
media shipments available upon request), and all
the features of eConnect. 24x7x365 upgrade
option extends coverage to after-hours, weekends
and holidays.
eConnect SM
Online resources including
unlimited web support requests (one business
day response), web downloads, and Technical
Reference DVD collection.
With TechConnect, you will also receive
the following benefits:fi
• Simplify management of your support coverage
- Combine all support for your site under
one agreement
- Choose support coverage based on seven product
families, not thousands of individual products
- Easily upgrade service levels, add options, or
change product coverage without purchasing
a new agreement
• Reduce downtime duration through improved
availability of technical resources and
troubleshooting specialists
• Improve productivity through better utilization of
maintenance personnel and automation equipment
• Decrease time to market through faster integration
of new equipment and systems
remote support
services
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Standard Products
Automation Control Products
Current and legacy programmable controllers | Operator Interface | I/O | Networks
Allen-Bradley Drives Control Products
Current standalone Allen-Bradley drives and programming software
Reliance Drives Control Products
Current and legacy standalone Reliance1
drives
Industrial Motion Control Products
Current and legacy rack-based motion products Servo drives2
ss | Programming software
CNC System Motion Products
Current and legacy system motion products and programming software
Advanced Software
HMI/Communication Software | Information Automation Software
Application Software | Process Software
Specialty Products
Specialty products include those with a small installed base, that require application-
level support, or non-Rockwell products.
1
Software updates not included for Reliance products. PriorityConnect service level not available.
2
Support for Electrocraft servo drives is available 8a-5p CST; Support for Creonics servo drives is
available 8a-5p EST. Standalone servo drives do not require an Automation
Control support agreement.
NOTE: For a complete list of products covered under TechConnect Support, go to www.
rockwellautomation.com/services/phone/supportedproductfamilies.html
TechConnect Product Families.
72
eConnect
DirectConnect
Priority Connect
TeamSupport
TeamSupport 360
increasing value/benefits
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Support
TeamSupport™
Services are a customizable service that
delivers remote technical support through a team of senior
engineers designated to support your key application
or entire facility. In addition to product expertise, the
designated team is familiar with your automation system(s)
and maintenance practices. Knowledge of your automation
systems is gained by reviewing your documentation and an
on-site review of your automation equipment and process.
When you need support, your calls are routed directly to
the designated support team through a unique TeamSupport
phone number. To expedite problem resolution, broadband
connectivity is used to link the Rockwell Automation support
team directly with your supported application(s).
Similar to TeamSupport, TeamSupport 360 Services add
proactive remote monitoring of critical alarms and process
parameters by a designated team of application support
engineers. Typically applied to manufacturing processes
with a high cost of downtime, TeamSupport 360 drives
Overall Equipment Effectiveness and helps optimize
human performance.
A continuous broadband connection links the TeamSupport
360 command center to the intelligent devices (e.g.,
controllers, drives, HMIs, etc.) controlling your key
manufacturing process. Combining engineering experience
with software-based diagnostic tools, our team will
proactively monitor your process 24x7x365 and immediately
notify your plant personnel of critical alarms and suggest
corrective action. With TeamSupport 360, in the unlikely
event an issue cannot be resolved remotely, Rockwell
Automation will dispatch a local field service engineerfi
at our expense.
www.rockwellautomation.com/services/phone
E-Safe Four levels of phone support for your legacy Entek products.
E-Safe Platinum provides you 24/7 phone support and free loaner equipment.
Can be customized to include additional support, training, and consulting services.
E-Safe Gold provides you priority access to our world-class customer support team,d
regular product updates, and annual calibration and extended warranty on Entek instruments,
plus all E-SAFE Silver features.
E-Safe Silver provides you access to our customer support team as well as regularr
maintenance and enhancement updates to your products and annual calibration services for
registered products. E-safe Silver also includes Web downloadable hot-fixes (for immediatefi
corrective action to known software problems) and discounts on instrument rentals and repairs.
E-Safe Bronze provides you phone support and other entitlements for software products thate
will no longer be updated. Rockwell Automation is committed to supporting these products
until you upgrade to a newer generation product.
73
TeamSupport™
/TeamSupport 360 Services
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74
onsitesupport
services
Preventive maintenance, troubleshooting, repair
and startup services performed by factory-trained
Rockwell Automation field support engineers
Each company’s support needs are different. That’s why we offer
comprehensive OnSite Support Services for installing, operating and
maintaining a wide variety of current and legacy automation equipment,
including the latest Rockwell Automation products based on our industry-
leading integrated architecture platform. These services provide the help
you need, how and when you need it. Whether 24x7x365 Callout Service,
an Extended Parts and Labor Warranty, or a full-time Embedded Engineer,
we’ll work with you to determine and provide the right support solution that
best helps your company meet the challenges of today’s industrial world.
Extended Parts and
Labor Warranty
With an Extended Parts and Labor Warranty from
Rockwell Automation, you won’t have to worry
about unexpected breakdowns or equipment failure.
Our programs include all replacement parts, repair
labor and local travel for up to five additional yearsfi
on select Rockwell Automation control equipment
and drives. If a problem occurs, our dispatch
center will immediately send an experienced,
factory-trained engineer to your site to perform all
repairs and restore operation as quickly as possible.
Extended Parts and Labor Warranty includes:
• Unlimited troubleshooting and repair
services by factory-trained technicians
(8 am - 5 pm local time, M-F*)
• No additional charge for local travel
• Procurement and installation of all replacement parts
- Genuine Rockwell Automation replacement parts
- No additional charge for parts
* additional charge for after-hours service
ProtectionPlus Drives Startup
System integration and start-up does not need to be
complex and time consuming. With ProtectionPlus
Drives Start-up Services from Rockwell Automation,
companies can leverage the extensive product and
industry experience of our field support engineers tofi
quickly commission selected drives and reduce the
time between integation and actual start-up. A one or
two year extended warranty is included depending on
the drive covered. ProtectionPlus includes:
• Verification of proper drive/motor installation,fi
control/power wiring, AC voltage and
distribution network
• Grounding checks
• Power-up, drive checks and setup
• Drive configuration/tuning to meet specififi cfi
application requirements
• Adjustment of operating parameters for
optimal performance
• Documentation of drive and motor nameplate
information, application information, drive settings
and operating parameters
For more information, go to www.rockwellautomation.com/services/onsite
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75
PerformancePlus
Preventive Maintenance
PerformancePlus Preventive Maintenance puts
Rockwell Automation field support engineers atfi
your site proactively for a scheduled number of
visits throughout the year. During each visit, our
engineers perform a predefined set of preventivefi
maintenance activities to help maximize the
availability, reliability and efficiency of yourfi
automation equipment including programmable
controllers, AC and DC drives & motors, medium
voltage drives, motion control, and related
peripheral devices. PerformancePlus includes:
• Documentation of system specificationsfi
• Control, electrical, and mechanical inspection
of automation systems and equipment
• Drive calibration and adjustment (if applicable)
• Software program revision check,
back-up and verificationfi
• Communication integrity check
• On-the-job training for equipment operators
and maintenance staff
• Priority response for emergency repairs
• Logbook of equipment performance and
maintenance process (see sample below)
• Regular program status/summary reviews
including progress against predefined goalsfi
and objectives
Support
Embedded Engineer
The Embedded Engineer program provides a full
time Rockwell Automation field support engineerfi
at your site for an uninterrupted period of time.
On site continuously, an Embedded Engineer
provides a wide range of predictive, preventive
and reactive support services to help meet your
maintenance needs. Embedded Engineers can
also help you meet future goals by improving
your internal troubleshooting and maintenance
capabilities and providing recommendations on
the most effective maintenance strategy for your
operations.
Conversion Services
From the initial planning stages through
installation, start-up, operation and maintenance,
you can count on Rockwell Automation to help
you successfully convert existing programmable
controllers, HMI, drives and motors to newer
technologies — and fully realize the benefits offi
those technologies.
On-site Conversion Services are available for:
• Replacing an AC or DC drive with current
technology (one-to-one)
• Replacing a PLC®
controller with current
technology (one-to-one)
• Updating automation software and
communication/HMI technology
• Converting an analog PLC controller, drive,
or HMI product to its digital counterpart
• Implementing or converting a network for
your automation assets
Callout Services
Day or night, Rockwell Automation field supportfi
engineers across the globe are available for
dispatch – as needed – to help you troubleshoot
and resolve unplanned downtime events or
problems affecting your critical operations.
To request dispatch, see the inside back cover
for local contact information.
ABC Company
PerformancePlus Preventive Maintenance - Customer Information
PM Goals &
Objectives
Date Set:
Date Set:
PLANT/ PLANT AREA/ MACHINE:
Compiled by:
Goals & Objectives:
Compiled by:
Goals & Objectives:
ABC Company
PerformancePlus Preventive Maintenance - Summary and Recommendations
Recommended
Actions
Between Date Set:
Visits
Comments:
Date Set:
Comments:
Date Set:
Comments:
Date Set:
Comments:
Key Customer Contact:
Recommended Action:
Recommended Action:
Recommended Action:
Recommended Action:
ABC Company
PerformancePlus Preventive Maintenance - Equipment Checklists (PLC)
Chassis Date Performed
Configuration Support Engineer
Chassis Catalog Number
Backplane
Current
Backplane
Current
Backplane
Current
Module
Power Revision
3.3 V (amps) 5.1V (amps) 24V (amps) (watts) 20-pin 36-pin Direct Rack
Rack
Power Supply
Slot 0
Slot 1
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Slot 8
Slot 9
Slot 10
Slot 11
Slot 12
Slot 13
Slot 14
Slot 15
Slot 16
Totals
I/O Termination Connections
Compiled by:
Goals & Objectives:
Comments:
Recommended Action:
Recommended Action:
Chassis Catalog Number
Backplane
Current
3.3 V (amps)
Rack
Power Supply
Slot 0
Slot 1
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Pd Pv Re
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76
network
Optimize the performance, reliability and
security of your control networks
& security
services
Our specially-trained network specialists apply GAMP
standards (Good Automated Manufacturing Processes)
throughout your control network life cycle – from
design to validation to maintenance – to ensure your
production data keeps moving reliably and securily
across your plant and throughout your enterprise.
Network Design
Network Design Services begin with an assessment of
your business objectives by our experienced network
specialists to identify functional and informational
requirements for your network. Once your requirements
are determined, a detailed network specification isfi
created which includes:
• IT and control network specificationsfi
• Identification of all/any business, SCADA,fi
IT, video, or other requirements
• Performance characteristics (network
capacity, bandwidth, utilization and
expansion requirements with calculations)
• Hardware, configurations and mediafi
• Access and Authentication policies
• Switching, isolation, firewall, VLANfi
and port security
• Redundancy, fault tolerance, and
recovery time
• Diagnostics and monitoring
• Explanation of security requirements
The specifications form the basis for your networkfi
topology design, which you will receive along with all
project documentation including the implementation
schedule and cost.
Network Design Review
Will your existing design meet your functional
requirements? A Design Review will ensure your
architecture and specified components will deliverfi
the network performance you expect by thoroughly
examining your business objectives, functional/
informational requirements, network drawings,
hardware/software specifications and logicalfi
network configuration.fi
Network Evaluation
Evaluating the performance of your existing system is
the first step to complete network health. Our Networkfi
Evaluation services offers comprehensive design
analysis, tests, and measurements to determine if the
operation of your existing system is consistent with your
functional requirements and if it has the bandwidth and
architecture to handle additional network traffic.fi
Pd Pv Re
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77
Networks&Communications
Baseline and Annual Performance Evaluations
The Baseline Evaluation will determine if your
architecture has the capacity to handle additional
network traffic, the installation is within specififi cation,fi
and the performance of your network is within
your operational requirements. When performed
on an annual basis, Baseline Evaluations also act
as a maintenance compliance assessment to ensure
consistent, reliable operation year after year.
Network Health Check
Performed in one day without interruption to your
production, a Network Health Check is a quick,
systematic review that rates your current network
based on five major criteria. Existing problems andfi
potential risks are identified and a recommendedfi
remediation path is provided.
Network Validation
Network Validation is a comprehensive analysis of
your network to verify its installation and operation
is consistent with network specifications defifi ned byfi
the associated governing bodies. A detailed report
includes all measurement and test results, analysis of
results, summary of findings, and recommendationsfi
for remediation.
Network Troubleshooting and Repair
When you have a network problem that can’t be
resolved, our network specialists can help you
quickly identify and correct the issue to restore
system performance to your requirements.
Security Services
Industrial automation and control systems, like IT
systems, are vulnerable to security issues, both
intentional and unintentional. However, traditional
means of securing business systems are often
unsuitable for the automation environment.
Through the following suite of Security Services,
Rockwell Automation will help you implement your
automation and control system security project or
manage your entire security program.
Controls Security Assessment
The Controls Security Assessment is a key first step infi
your overall security deployment plan. This assessment
utilizes industry and Rockwell Automation best practices
to identify security issues at the plant and enterprise
level and provides recommendations to mitigate risk.
Controls Security Seminar
If you are implementing and managing your own
security program, Rockwell Automation will provide
an intensive seminar to address your specific securityfi
issues and program implementation process.
Security Program Development/Deployment
Rockwell Automation can deploy your entire security
program including Controls Risk Assessment, Security
Architecture and Design, Security Policy and Program
Design, Training, Program Implementation and Return
on Security Investment and Cost Benefit Analysis.fi
Security Incident Response
If you experience a security-related event, Rockwell
Automation will help you determine its cause and
how to prevent it from recurring.
GOOD HEALTH.
This DeviceNet™ signal
indicates normal operation
within all specifications andfi
agency guidelines.
BAD HEALTH.
This network has multiple problems –
a crossed differential signal from
CANHigh and CANLow, ground loop
distortion and excessive reflectionsfl
(from poor connections).
HOW HEALTHY IS
YOUR NETWORK?
Network Evaluation
services can identify a wide
range of hidden problems
adversely affecting your
network performance –
and all equipment on it.
Bad Network Health Good Network Health
services/networks
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78
The complete, cost-effective solution for
remotely connecting to control systems
dial-in
modems
remote
access
Allen-Bradley®
Remote Access Dial-in Modems allow you to quickly
connect to your control system from any standard phone line,
improving your ability to respond to critical situations without
actually being on site.
Now you can eliminate those weekend trips to the plant, or costly
travel to field locations. From home, your offifi ce or another facility,fi
you can easily:
• Make program changes
• Upload and download new programs
• Update firmwarefi
• Collect data
• Monitor system status
Remote Access Ethernet Modem
Remotely support devices on Ethernet with the Remote Access
Ethernet Modem. The Dial-In Ethernet modem combines a four
port managed switch with a 56K modem, allowing a remote
connection to your Ethernet network. The built-in management
interface allows flexibility when implementing the device to yourfl
new or existing application.
Remote Access Serial Modem
Remotely connecting to your control system using an off-the-shelf,
computer store modem can often be a difficult task. That’s why wefi
created the Allen-Bradley Remote Access Dial-in Modem Kit. Remote
Access Dial-in Modem Kits are specifically designed for remotefi
connection to control systems and include everything you need
(Quick Start Guide, AC adapter, required cables) to easily
connect the first time, and every time. Standard and pagingfi
models available.
Pd Pv Re
www.rockwellautomation.com/services/rmd/modemkits.html
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79
Networks&Communications
9300-RADES
Remote Access
Ethernet Modem
9300-RADKIT
Remote Access
Serial Modem
9300-RAPMKIT
Remote Access
Serial Modem w/Paging
Description
Features
Rated Voltage
Connector/Body
Dimensions
Additional
information
REMOTE ACCESS
MODEMS
Features
Environmental
Operating Temperature
Storage Temperature
Weight Compliance
Power Requirements
Network Ports
DTE Rates (Asynchronous)
Line Rates (V90)
Line Rates (V.34)
Error Control/Data Compression
Phone Interface Connection
Phone Line Requirements
Transmit Level
Carrier Detect Threshold
Switch Characteristics
Routing Characteristics
Protocols
Switches
Facsimile Compatibility
Facsimile Operating Speeds
• Compact, DIN-rail mountable design
• Connection speeds up to 56K
• Remote configuration
• Flexible power requirements
• Multiple cables and adaptors are
provided for connection to a variety of
control system components
• Remote configuration (allows recon-
figuration of a remote modem to match
changes in the control system)
• Password protection, password with
callback and Caller ID (protects control
systems from unauthorized access)
• Profile selection switches (allow prepro-
grammed profiles to be selected without
connecting to a computer)
• Remote configuration
• Multiple cables and adaptors are provided
for connection to a variety of control
system components
• Remote configuration (allows recon-
figuration of a remote modem to match
changes in the control system)
• Password protection, password with
callback and Caller ID (protects control
systems from unauthorized access)
• Profile selection switches (allow prepro-
grammed profiles to be selected without
connecting to a computer)
• FCC part 68, Part 15-class b, UL/CSA/
IC Certified, CTR 21, UL Class 1 Div. 2
• 8 to 48VDC
(100 MA at 24V, 200MA at 12V)
na
• 230.4K,115K,57.6K, 38.4K, 19.2K,
9600, 4800, 2400,1200 and 300 bps
• FCC part 68, Part 15-class a, UL/CSA/IC
Certified, CTR 21, CE, UL Class 1
Div 2 Hazardous
• 8 to 48VDC
(200 mA at 24V, 300mA max)
• 4 RJ-45 10/100 full/half duplex jacks
• Host to DSP - Internal high speed
serial interface
• FCC part 68, Part 15-class b,
UL/CSA/IC Certified, CTR 21
• 8 to 48VDC
(100 MA at 24V, 200MA at 12V)
na
• 230.4K,115K,57.6K, 38.4K, 19.2K,
9600, 4800, 2400,1200 and 300 bps
na
na
na
• 4 Default Profile Selection Switches,
Power Switch
• ITU Group 3 fax machines and fax
modems, ITU V.17, V.29, V.27ter,
V.21Channel 2, T.30, T.4, EIA-578
Class 1 compatibility for fax software
• Send/receive: 14,400 bps to 2400 bps
• VLAN, QoS, IGMP, Port Mirroring
• Automatic Dial-Out, DHCP, BOOTP,
PAP, CHAP
• TCP/IP, PPP, RIP, NAT, Telnet, FTP,
DHCP, BOOTP
na
na
na
na
na
na
• 4 Default Profile Selection Switches,
Power Switch
• ITU Group 3 fax machines and fax
modems, ITU V.17, V.29, V.27ter,
V.21Channel 2, T.30, T.4, EIA-578
Class 1 compatibility for fax software
• Send/receive: 14,400 bps to 2400 bps
0 TO 60º C (32 TO 152º F)
-20 TO 70º C (-4 TO 158º F)
1.5 LBS.
56K thru 28K bps
28.8K thru 2400 bps
V.42, V.42bis MNP Classes 3,4
RJ11C
Unconditioned PSTN dial-up
Dial Line: -10dBm fixed
-10 to -43dBm
• Data compression increases phone line
throughput by 40%
• 17 diagnostics LEDs report system status
and network activity
• VLAN capability reduces network traffic
• Network debugging with port mirroring and
port diagnostics
• IGMP Snooping to minimize network traffic
• Dial-out capability to route packets to other
networks
• Multiple levels of security:
• DHCP/BOOTP server (services up to 30
nodes on your network)
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Maximize your knowledge of automation
and related technologies and successfully
apply that knowledge on the job
training services
Instructor-led Training
Standard Open Enrollment Courses
You can choose from over 250 open enrollment
classes designed around the use of automation
technologies by job function. General industrial
courses are also available including Basics of
Electricity, Safety Compliance, Applied Hydraulics,
as well Rockwell Automation technologies.
Classes are conducted at Rockwell Automation
and partner locations.
Tailored Training Courses
Developed in a modular format, Tailored Training
allows you to select from 1600 specific lessons infi
our standard courses to build the class content that
will meet your specific needs.fi
Custom Courses
When standard and tailored training
courses won’t meet your needs,
Rockwell Automation can develop
custom curricula to your exact
specifications. Custom coursesfi
include content specificfi
to your automation environment and can be
delivered using your automation equipment,
software, and system configuration. This highlyfi
effective training solution is often required for your
critical plant areas or applications.
On-site and Private Training Courses
Any instructor-led course can be conducted at
your plant or private location, eliminating
the time and cost to travel.
On-site courses also offer the exclusive benefit offi
free pre-and post-tests, which benchmark a student’s
knowledge before and after training. The data
captured from the tests enables you to qualify the
return on your training investment.
Embedded Instructors
If you have a large production environment with
ongoing and diverse professional development
needs, you can obtain an embedded Rockwell
Automation instructor to meet your continuous
training needs. Embedded instructors can deliver
standard, tailored and custom courses.
Self-paced Training
Computer-based Training
You can obtain hands-on training on a variety of
Rockwell Automation products and automation-
related topics through our computer-based training
courses on CD-ROM. Our computer-based training
provides engaging, interactive exercises and
simulations to enhance your learning experience
- right at your desk. Post-tests measure your
knowledge transfer after completion of each course.
80
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TrainingServices
TRAINING VOUCHERS
TRAINING SERVICES CATALOG
The Rockwell Automation Training Services catalog
is your source for complete descriptions and
ordering information on all of our Instructor-led
Training courses, Self-paced Training products and
other training-related services.
For your copy of the Rockwell Automation Training
Services catalog, contact your local Rockwell
Automation sales offices or authorized Allen-Bradleyfi
distributor. To download the catalog, go to:
www.rockwellautomation.com/services/training
Maximize your training budget by prepurchasing
vouchers for Rockwell Automation training courses
and products at a discount (up to 20%). Vouchers
can be used any time within one year. Usage can
be tracked online.
www.rockwellautomation.com/services/training/
savingsprograms.html
81
Pd Pv Re
Self-paced Training Continued
Web-based Training
With Rockwell Automation Web-based Training, you can utilize the
power and flexibility of the Internet to obtain on-demand trainingfl
courses at your convenience.
Job Aids
You can quickly obtain essential job task information to minimize
automation-related problems with Rockwell Automation Job Aids.
These guides are published in a compact, durable format and include
an extensive selection of Procedures Guides, Troubleshooting Guides,
and Reference Guides covering a diverse range of technologies
and job functions.
Workstations
Training workstations are the ideal tool to reinforce and practice
maintenance, troubleshooting, and programming skills, train new
employees, and ease the transition from one technology to another
in a plant.
If you are looking for hands-on, job performance support, Rockwell
Automation workstations are available for a variety of technologies
and can be customized to meet your needs.
Competency Testing
With competency testing, you will ensure your staff has acquired the
necessary automation knowledge and skills to perform required tasks.
You can select from standard or custom evaluation solutions available
in hard copy or online formats.
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82
TrainingServices
Curriculum Maps
Curriculum Maps show a recommended training path based on your job task responsibilities
within a technology area. For example, the courses in the maintain track are designed for and
instruct students on maintenance-related responsibilities.
To use the curriculum maps:
1. Identify the recommended courses in the Understand track
Courses in the Understand track apply to all students and provide the prerequisite
knowledge required to successfully complete courses in both the Maintain and Program and
Design tracks. It is highly recommended you complete the courses in the Understand track
before progressing to the other tracks in the curriculum.
2. Follow the Maintain or Program and Design tracks via the solid black lines.
NOTE: When presented with a choice of two courses, select the one most appropriate one by reviewing
the course description or using the Course Selection Tool (www.rockwellautomation.com/services/
training/tool.html) to assess your knowledge on the subject. Courses connected by a dashed line indicate
that one of the two courses is optional. Skipping the course will not adversely affect your performance in
other classes in the track.
ContolLogix®
/RSLogix™
5000
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83
TrainingServices
SLC™
/RSLogix™
500
Understand
Maintain
Program and Design
Related e-Learning Products
SLC 500 and
RSLogix 500
Maintenance
and Troubleshooting
CCPS43 4 Days
PLC-5/SLC 500
and RSLogix
Fundamentals
CCP122 2 Days
SLC 500 and
RSLogix 500
Advanced Maintenance
and Troubleshooting
CCPS45 4 Days
SLC 500 and PLC-5
Communications
CCPS65 1 Day
9393-RST500OFENE
(9393-RST500OFENF)
SLC 500 and
RSLogix 500
Advanced
Programming
CCPS42 4 Days
RSTrainer for
RSLogix 500
Software-
Offline Programming
RSLogix 500
Software-
Offline Programming
9393-RST500ONENE
(9393-RST500ONENF)
RSTrainer for
RSLogix 500
Software-
Online Monitoring
9393-RST500DSENE
(9393-RST500DSENF)
RSTrainer for
RSLogix 500
Software-Documenting
and Searching
RSLogix 500
Software-
Online Monitoring
9393-RSCOMP500
RSCompanion
for SLC 500 and
MicroLogix Processors
9393-RSTLINX
(9393-RSTLINXENF)
RSTrainer for
RSLinx Software
9393-RSTSLC
(9393-RSTSLCENF)
RSTrainer for
SLC Fundamentals
SLC 500 and
RSLogix 500
Programming
CCPS41 4 Days
PLC-5®
/RSLogix™
5
Understand
Maintain
Program and Design
PLC-5 and RSLogix 5
Programming
CCP410 4 Days
PLC-5 and RSLogix 5
Maintenance
and Troubleshooting
CCP412 4 Days
PLC-5/SLC 500
and RSLogix
Fundamentals
CCP122 2 Days
PLC-5 and RSLogix 5
Advanced
Maintenance and
Troubleshooting
CCP409 4 Days
9393-RSTLX5
(9393-RSTLX5ENF)
SLC 500 and PLC-5
Communications
CCPS65 1 Day
PLC-5 to ControlLogix
Transitioning
CCP710 2 Days
RSTrainer for
RSLogix 5 Software
PLC Fundamentals
9393-RSTLINX
(9393-RSTLINXENF)
RSTrainer for
RSLinx Software
PLC-5 and RSLogix 5
Advanced
Programming
CCP411 4.5 Days
Visualization
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84
TrainingServices
Drives
Understand
Maintain
Program and Design
1395 Drive
Maintenance and
Troubleshooting
CDD131 3 Days
1336 PLUS ll
Maintenance and
Troubleshooting
CCA137 3 Days
1397 Drive
Maintenance and
Troubleshooting
CDD132 3 Days
PowerFlex 700
Vector Control
Maintenance and
Troubleshooting
CCA163 1 Day
PowerFlex 700S
Phase ll Maintenance
and Troubleshooting
PFX700S2-LD 3 Days
PowerFlex 700S
Phase l Maintenance
and Troubleshooting
PFX700S-LD 3 Days
AC/DC Motors and
Drives Fundamentals
CCA101 2 Days
AutoMax
Maintenance and
Troubleshooting
RE0520 4 Days
1336 IMPACT
Troubleshooting
CCA132 1 Day
1336 PLUS
Maintenance and
Troubleshooting
CCA129 1 Day
DC Drives and
AutoMax/DCS
Introduction
RE0505 4 Days
1336 IMPACT Startup
CCA133 1 Day
1336 IMPACT
Programming
CCA138 1 Day
9393-RSTACD
(9393-RSTACDENF)
RSTrainer for
Fundamentals of
AC/DC Motors
and Drives
RSTrainer for
Fundamentals of
AC/DC Motors
and Drives
AutoMax
Programming
Fundamentals
RE0523 4 Days
PowerFlex 700
Vector Control
Configuration and
Startup
CCA161 1 Day
1336 IMPACT
Communications
CCA135 1 Day
PowerFlex 700
Vector Control
Communications on
DeviceNet
CCA162 1 Day
PowerFlex 700
Vector Control
Communications on
ControlNet
CCA164 2 Days
IntelliCENTER
CCI105-LD 3 Days
Networks
Understand
Maintain
Program and Design
RSLogix 5000 Level 4:
Motion Programming
Using Ladder Logic
CCN142 3 Days
Kinetix 6000
Maintenance and
Troubleshooting
CCN200 2 Days
Introduction to
Automation and
Integrated Architecture
CIA101 2 Days
Motion Control
Fundamentals
CCN130 2 Days
CNC 9/Series
Maintenance
CNN162 4.5 Days
1394 and
GML Commander
Maintenance and
Troubleshooting
CCN183 4 Days
Advanced Motion
Programming
RSTrainer for
RSLogix 5000
Software - Motion RSLogix 5000
Software - Motion
CCN190-LD
9393-RSTLX5KMOT
(9393-RSTLKMOTENF)
2 Days
CNC 9/Series
Programming
CNN161 4.5 Days
Ultra3000
Programming
CCN191-LD 1 Day
1394 and
GML Commander
Programming
CCN184 4.5 Days
Motion Control
SM Selection Final R1.indd 84SM Selection Final R1.iinal R1.indd 84ndd 844 7/25/06 5:05:03 PM7/7/2/25/06 5:05:5/5/0/06 5:05:03 PM03 PM

85
TrainingServices
Process
Control
Condition Monitoring
Safety
Understand
Maintain
Program and Design
GuardPLC 1600/1800
Controller Systems
Fundamentals
SAF-PLC101 1 Day
2030 ElectroGuard
Safety Isolation System
Maintenance and
Troubleshooting
Fundamentals
SAF-ELE101-LD 1 Day
GuardPLC 1600/1800
Controller Systems
Maintenance
and Troubleshooting
SAF-PLC102 1 Day
GuardLogix
Maintenance
and Troubleshooting
SAF-LOG102 2 Days
ControlLogix
System Fundamentals
CCP146 2 Days
2030 ElectroGuard
Safety Isolation System
Authorized
Maintenance and
Troubleshooting
SAF-ELE102-LD 2 Days
Project Development
CCP143 4 Days
GuardPLC 1600/1800
Controller Systems
Programming
SAF-PLC103 1 Day
GuardLogix
Application
Development
SAF-LOG101 2 Days
SM Selection Final R1.indd 85SM Selection Final R1.iinal R1.indd 85ndd 855 7/25/06 3:10:31 PM7/7/2/25/5/0/06 3:10:6 3:10:31 P31 PMM

repair
services
pp
Your only source for genuine Rockwell Automation
remanufactured products and factory enhancements.
& renewal
parts
REMANUFACTURING SERVICES
Every Allen-Bradley®
and Reliance®
product you
send for repair will undergo the Rockwell Automation
remanufacturing process. Exclusive to Rockwell
Automation, this guaranteed process assures your
complete satisfaction by performing the following steps:
Receipt and Verificationfi Catalog numbers,
series, and revision levels are verified and a barfi
code is applied for easy tracking of repair history
and order status.
Revisions and Enhancement Your module
is cleaned, inspected, and updated to the latest
applicable hardware and copyrighted firmwarefi
revisions. This helps extend equipment life and
ensure integration with newer products.
Component Verification/Replacementfi
Rockwell Automation Remanufacturing Services utilize
a proactive and predictive maintenance approach.
Suspect components are tested, verified and replacedfi
with Rockwell Automation specified quality componentsfi
if needed. Damaged components will be replaced
by parts that have been pre-screened, burned-in,
and specifically selected for Rockwell Automation.fi
Dynamic Functional Testing Specially-trained
technicians evaluate operational status using dedicated
test equipment including parametric testing.
Environmental Testing Dynamic environmental
testing identifies intermittent problems not readilyfi
apparent, helping prevent premature failures in
the future.
Final Quality Control Inspection All equipment is
cosmetically cleaned and visually inspected by Quality
Control Inspectors for complete compliance to Rockwell
Automation standards.
Shipping Modules are placed in custom-engineered
anti-static bags and containers to help protect them
against static discharge during shipment.
All equipment remanufactured
by Rockwell Automation receives
a 12-month warranty.
When your Rockwell Automation equipment malfunctions or fails, which repair service will you trust? Only
Rockwell Automation, the original equipment manufacturer, can provide complete, cost-effective remanufacturing
services and factory enhancements that extend equipment life, while enhancing its performance and compatibility.
Rockwell Automation customer surveys indicate products repaired by third-party companies can result in three
times the warranty failures compared to products remanufactured by Rockwell Automation.
86
SM Selection Final R1.indd 86SM Selection Final R1.indd 8d 866 7/25/06 3:10:40 PM7/7/2/25/5/0/06 3:10:40 P:10:40 PMM

RepairServices&RenewalParts
EXCHANGE SERVICES
When you need a replacement part quickly,
you can rely on Rockwell Automation Exchange
Services. Through these services, you have
access to 15,000+ remanufactured Allen-Bradley
catalog items inventoried at our global network
of parts HUBs. These HUBS are strategically
located to quickly provide you with a replacement
product, even next day through our Advanced
Exchange Services. See inside back cover for
hub locations.
RENEWAL PARTS™
Through the Custom Classics program, you can
obtain popular Allen-Bradley, Reliance Electric,
Entek and ElectoCraft products that are no longer
mass-produced, but may be available from stock
or on a “made-to-order” basis.
REPAIRPLUS™
SERVICES
(Repair Services for non-Rockwell Automation Products)
With RepairPlus™
Services, you will have a single
source solution for all of your electrical, electronic,
mechanical, and servo product repairs. RepairPlus
provides you comprehensive repair services for over
80,000 items from 1500+ manufacturers. Each item
you send for repair (or we can pick it up through our
BoardRunner Pickup Service) goes through our Circuit
Performance Reliability diagnostics process that checks
the entire unit for damage, even if the source problem
is found early in the process. All repaired units are
covered by a full one year warranty that covers the
entire unit, not just the repaired components.
ASSET MANAGEMENT CATALOG
REPAIRTRAK™
PROGRAM
AC Drives ABB AC Technology Anyspeed ASEA Baldor Boston Gear Browning Burton Century Control
Techniques Cutler Hammer Danfoss Dart Controls Dayton Dynamatic Electromotive Sys Emerson EMS
gy y p g ygy y p
Inc Eurotherm Fincor Fuji Electric General Electric Graham Hansen Hitachi IDM Controls Indramat
Inland Motor Jaguar KEB Leeson Lenze Louis Allis Lovejoy Magnetek Mikki Pulley Minarik Mitsubishi
Motortronics Omron Parametrics Powertec Relcon Satronics Seco SEW-Eurodrive Square D Sumitomo
g gg
Telemecanique Toshiba U.S. Motors Vickers Volkmann Warner & Swasey Westinghouse Woods
Yaskawa York Zycron
DC Drives ABB Acrison Amicon Baldor BBC-Veritron Bodine Electric Borg Warner Boston Gear
Browning Burton Carotron Cleaver Brooks Contrex Control Techniques CSR Contraves Cutler Hammer
gg
Danfoss Dart Controls Doerr Electrol Emerson Eurotherm Extech Fenner Fincor Gaston County General
g qg
Electric Graham KB Electronics Klockner-Moeller KTK LTD Leesona Lenze Louis Allis Magnetek Meltex
Minarik Morse Muller P & H Parametrics Polyspede Powertron Punos Elektronik Randtronics Robicon
gg
Sabina Satronics Seco Siemens Southcon SSD Sterling Electric Stock Equipment Co Stromag U.S.
Motors Westinghouse Woods
PLC AEG Aromat Barber Colman Chrontrol Corp Control Techniques Cutler Hammer Facts Engineering
Fuji Electric General Electric Giddings & Lewis Klockner-Moeller Mitsubishi Modicon PLC Direct Schneider
g gg g
Siemens Texas Instruments Toshiba Westinghouse Yaskawa
gg
Servo Motors & Drives A.S.R. Servotron Advanced Motion Aerotech Atlas Baldor Baumuller
Compumotor Control Techniques CSR Contraves Emerson Fanuc General Electric Indramat Industrial
Drives Inland Motor Kollmorgen Lenze Mitsubishi Pacific Scientific Siemens Warner & Swasey Westamp
p q
Weld Controllers Robotron ICR Square D Dengensha ADC
Robot ABB ASEA Fanuc Rimrock Adept Nachi Kawasaki Trallpa Staubli
Distributed Control Systems Bailey Robotics Foxboro Honeywell
RepairTrak™
is a unique repair program that provides
the tools you need to operate a reliable electronic
remanufacturing program. Repairtrak includes:
• Repair tracking (prices, status, shipment)
• Analysis tools (probable cause, warranty reporting)
• Three year warranty on remanufactured equipment
• Boardrunner pickup service
A three year commitment is required to qualify for RepairTrak
Pd Pv Re
The Rockwell Automation Asset Management catalog is
your comprehensive source on all the products covered by
our Remanufacturing, Exchange, and RepairPlus services.
For your copy of the Rockwell Automation Asset
Management catalog, contact your local Rockwell
Automation sales ofﬁces or authorized Allen-Bradleyﬁ
distributor. To download the catalog,
go to www.rockwellautomation.
com/services/
assetmanagement.
SM Selection Final R1.indd 87SM Selection Final R1.ilection Final R1.indd 8ndd 877 7/25/06 3:10:42 PM7/7/2/25/5/0/06 3:10:6 3:10:42 P42 PMM

what’s nexta sneak preview at Strategic Maintenance
products and services coming in fall 2006 and
winter 2007 from Rockwell Automation
88
Knowing that your spare parts are in working order gives you peace of mind that
when a machine shuts down, you can restore operation quickly. Rockwell Automation
is developing a program to provide comprehensive testing services for suspect spare
parts inventory. Through this program, each unit sent through an authorized Rockwell
Automation Remanufacturing facility is tested and returned with a one year warranty.
Units that fail our inspection will be remanufactured. Once returned, you will
have conﬁdence in the integrity of your spares when the need arises to use themﬁ
within your facility.
SPARE PARTS INVENTORY ASSURANCE SERVICES
Process Control
• Foundation Fieldbus Basics
• Basic Process Control Using
Smart Instrumentation
• PID Loop Basics
Safety
• Mechanical and Electrical Machine
Safety Design and Implementation
• GuardLogix™ Maintenance
and Troubleshooting
NEW INSTRUCTOR-LED TRAINING COURSES
The following Instructor-led Training courses will be available fall 2006:
SM Selection Final R1.indd 88SM Selection Final R1.indd 8ndd 888 7/25/06 3:10:45 PM7/7/2/25/5/0/06 3:10:6 3:10:4545 PMPM

what’snext
89
Validating your safety system performs according to design requirements is an essential
element of an overall plant safety program.
Safety System Validation Services from Rockwell Automation will be tailored to meet your
needs – whether it’s a turnkey validation service or the expertise needed to develop a
comprehensive validation plan that can be used at commissioning and on a regular basis to
verify the performance of the safety system.
Your safety system validation will include the verification of 3rd party component approvals,fi
proper mechanical installation of components including safe distance verification and properfi
electrical installation relating to device inputs and outputs.
SAFETY SYSTEM VALIDATION SERVICES
Managing employee skills in a global environment can be difficult. For multiplefi
users and concurrent classes, the RSTrainer®
r 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 wayfi
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.
RSTRAINER®
STUDENT MANAGER ENTERPRISE EDITION
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what’snext
90
It is becoming increasingly difficult to manage change through confifi gurationfi
alterations including daily operations like troubleshooting, minor adjustments,
monitoring and temporary patches. Many devices have complex configurationsfi
and sophisticated programs while others can be configured remotely.fi
Today’s highly intelligent devices can provide great benefits in meeting yourfi
manufacturing goals, but administration of these same systems is becoming
increasingly difficult.fi
Releasing in early 2007, FactoryTalk®
kk AssetCentre software will provide 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 fifi lesfi
• configuring process instrumentsfi
• providing backup and recovery of
operating asset configurations.fi
The scaleable design of FactoryTalk AssetCentre allows for both easy expansion
of device counts and extensible feature sets and provides you an application
adaptable to small line applications or enterprise-wide installations.
Look for more information on FactoryTalk AssetCentre in the months to come.
FACTORYTALK®
ASSETCENTRE SOFTWARE
SM Selection Final R1.indd 90SM Selection Final R1.inddndd 900 7/25/06 3:10:45 PM7/7/2/25/5/0/06 3:10:45 PM5 PM

Get Support Now
PHONE SUPPORT
1
, REPAIR PARTS, INSTRUCTOR-LED TRAINING REGISTRATION
and ONSITE SUPPORT CALLOUT SERVICES
U.S./Canada 1.440.646.3434
Canada (CALLOUT SERVICES ONLY)
Weekdays 8am-5pm local time Call local Rockwell Automation Sales Office
2
Weekends, holidays, weekdays 5pm-8am local time 1.800.422.4913
Outside U.S./Canada Call local Rockwell Automation Sales Office
2
WEB SUPPORT AND ONLINE TOOLS
Support Home www.rockwellautomation.com/support
Rockwell Automation Knowledgebase http://support.rockwellautomation.com/knowledgebase/
Online Support Requests1 http://support.rockwellautomation.com/supportrequests/
MySupport - Electronic Update and Technote Notification http://support.rockwellautomation.com/mysupport.aspfi
Rockwell Software Product Updates1 http://support.rockwellautomation.com/webupdates/
Flash Firmware Updates1 http://support.rockwellautomation.com/controlflash/fl
Repair Parts Search www.rockwellautomation.com/repair
Training Schedules www.rockwellautomation.com/training
Technical Phone Support Center
Field Support Central Dispatch (U.S.)
Remanufacturing Depot
Exchange Hub
Rockwell Automation Sales Office, Field Support Dispatch
(outside U.S.) and/or Open Enrollment Training Location
The global Rockwell Automation Services & Support network includes over 1000 field support engineers, phone support specialists,
asset management professionals, training instructors and repair technicians. Our broad network of automation specialists utilize the
global resources of Rockwell Automation to provide local, award-winning services and support for your automation equipment.
91
1 TechConnect Support may be required. If you have purchased Techconnect Support, please consult your users guide for additional information on using this feature.
2 Go to www.rockwellautomation.com/locations and select your country for local contact information. Locations are subject to change without notice.
SM Selection Final R1.indd 91SM Selection Final R1.indd 911 7/25/06 5:13:32 PM7/7/2/25/5/0/06 5:13:32 P:32 PMM

Look for new issues of these
Rockwell Automation magazines
throughout 2006.
www.ab.com
Click on Newsletters
and Magazines
Copyright ©2006 Rockwell Automation, Inc.All Rights Reserved. Printed in USA.
The following are trademarks or registered trademarks of Rockwell Automation, Inc:
Allen-Bradley, ArmorPoint, ArmorStart, Atlas, Cadet, Centurion, CompactLogix, Control Tower Stack Lights, ControlLogix, Dodge,
DriveGuard, ElectroGuard, Elf, Ensign, Ferrogard, GuardLogix, Guardmaster, GuardMotion, GuardPLC, GuardShield, Kinetix, Lifeline,
Listen.Think.Solve., Logix, MatGuard, MicroLogix, Minotaur, PanelView, Pico, Pico GFX, PowerFlex, Prosafe, Reliance Electric, Rockwell
Automation, Rockwell Software, Rotacam, RSLogix 5000, RSLogix Guard PLUS !, RSView, Safedge, SafeShield, Safety Now, SafeZone
Multizone Laser Scanner, Self-Monitoring, Sipha, Spartan, Sprite, Trojan, Zero-Force
The following are trademarks not belonging to Rockwell Automation and belong to their respective companies and/or organizations:
CIP Safety, ControlNet, DeviceNet Safety, Ethernet, Ethernet TCP/IP, EtherNet/IP Safety, Gerstlauer, International Automation, S & D
SM Selection Final R1.indd 92SM Selection Final R1.inddl R1.indd 922 7/25/06 3:10:45 PM7/7/2/25/5/0/06 3:10:4545 PMPM

StrategicMaintenance7-28-07

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