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Contents
A4 Industrial networking expands
PLC functionality
Combining real-time Ethernet with visualization, control, and
communication capabilities allows PLCs to open the door to a
new level of visibility and control for manufacturers.
A8 Optimizing control panel design,
construction
Modern control panel wiring methods can reduce the costs
of manufacturing and ownership.
A13 VFD bypasses and backups:
Which should you use?
Advanced motor protection and consistent energy savings
are possible with true redundancy.
C OMME NT
Of PLCs, control panels, and VFDs
D
ick Morley is known as the father of the
PLC because of his work at Bedford and
Assocs. in 1968. Almost half a century
later, the PLC is the mainstay of industri-
al automation—in one form or another. Whether
it’s a brick, micro, or a high-horsepower PAC,
the PLC “has been the workhorse in automation
and manufacturing industries across the board
Jack Smith for many years,” to borrow from the words of the
Edit or authors of this issue’s cover story.
High-speed Ethernet allows bandwidth-hungry
technology such as motion control and video to
communicate with the systems that require their
functionality. As the authors point out, “Although
PLCs opened the door for on-the-floor visual
communication, it was their integration with
networking devices that offered manufacturers
a new level of visibility and control by combin-
ing real-time Ethernet with visualization, control,
A4
On the cover
PLCs ensure manufacturing operations run smoothly by
interfacing with sensors, machine guards, motion con-
trol systems, and advanced identification devices—and
that’s just for starters.
Courtesy: Turck
A8
and communication capabilities.”
The second article in this issue explains how
advancements in modern control panel wiring
methods can reduce the costs of manufactur-
ing and ownership. By increasing the number of
control panel components as well as simplifying
the wiring that connects them, material, labor,
and commissioning costs can be minimized, and
construction time can be reduced.
VFDs are among the devices that can inter-
face with PLCs. The third article in this issue
explains the history behind the need for bypass-
es. Although VFDs have become much more
reliable than when they were first introduced,
the bypass, which enabled users to operate
motors without the VFD, remains today in one
form or another. This article describes traditional
and electronic bypasses as well as redundant
VFD configurations.
Applied Automation August 2013 • A3
 cover story

Industrial networking expands

PLC functionality
Combining real-time Ethernet with visualization, control, and communication capabilities
allows PLCs to open the door to a new level of visibility and control for manufacturers.

By Randy Durick, Chris Vitale, and ing production quality and cost of operation.
Matt Boudjouk, Turck The benefits of the PLC are well known. Their contribu-

T
he days when manpower served as the brain
and brawn in manufacturing are long gone,
while human-machine interaction has become
commonplace on the factory floor. A prime
example of this is the PLC, which has been the
workhorse in automation and manufacturing
industries across the board for many years. By interfac-
ing with everything from sensors and machine guards to
motion control and advanced identification devices, PLCs
ensure operations run smoothly (see Figure 1). Through
the flexibility offered with PLCs, manufacturers can man-
age multiple machines at once—achieving a higher level of
integration and process automation machines and improv-
Courtesy: Turck
tions toward efficiency enhancement and the behind-the-
scenes support of industrial Ethernet make this heightened
control possible. Together, these technologies make com-
munication between humans and machine a seamless,
profitable combination. Consisting of various protocols,
industrial Ethernet was developed with deterministic capa-
bilities to provide a cost-effective alternative to legacy
automation systems.
With advanced capabilities, sophisticated functionality,
and simplified installation, the PLC is a cornerstone of
modern manufacturing. However, to effectively use these
devices, users must understand the crucial role networking
plays and the individual requirements that must be consid-
ered for an effective solution. Together, they form a unified
infrastructure that can extend from the administrative to
control- and floor-level networks, offering inherent scalabil-

ity to continue to meet growing industry demands.

PLC technology breakdown

Figure 1: PLCs ensure manufacturing operations run smoothly by
interfacing with sensors, machine guards, motion control systems,
and advanced identification devices—and that’s just for starters.
Since their inception, PLCs have become a keystone of
industrial automation, often serving as a vital link between
humans and machines. As control architecture continues
shifting and network technology keeps advancing, these
changes support integrated HMI-PLCs that leverage an
established and portable programming environment. As a
universal controller, PLCs can be programmed to perform
a variety of tasks—from starting and stopping motors to
mathematical computing operations. With the processing
power, data storage, and communication capabilities of
today’s modern computers, PLCs provide intelligent and
rugged field-level application control (see Figure 2). PLCs
are designed to act as miniature computers that can deliv-
er reliable operation in various challenging environments,
such as extreme temperatures, electrical noise, vibration,
and shock.
A PLC interacts with the environment it controls through
its I/O. PLC inputs accept signals from many types of sen-
sors, switches, and other control devices. The PLC makes
decisions based on the values of these input signals with
regard to the program that’s written to leverage its power
to make things happen in its environment. Historically,
PLC programs have been created in ladder logic—a lan-

A4 • August 2013 Applied Automation

guage that closely resembles a relay-
based wiring schematic. However,
modern PLC programming is not
limited to ladder logic. The results of
these decisions are sent to actuation
devices through the PLC’s outputs.
In many cases, the inputs provide
feedback to the PLC to enable these
decisions, while the outputs provide
the results of these decisions in the
form of something that can change
the process or environment.
PLC advantages: Implementing
PLCs offers numerous performance
benefits, such as reduced hardware Figure 2: Processing power, data storage,
requirements, increased efficiencies, and communication capabilities make mod-
and less waste. Modern PLCs are ern PLCs ideal solutions for delivering intelli- PLCs can connect the enterprise
highly customized solutions that can gent, rugged, field-level application control.
be tailored to individual control appli-
cations while consuming less real estate on the factory
floor (see Figure 3).
As a built-in controller, PLCs simplify installation
because they use less cabinet space. Also, visual displays
of many PLCs improve machine/operator interaction and
increase production efficiency. For example, local displays
coupled with easy-to-use interfaces on PLCs can provide
simple instructions for machine operators as well as a
means for data entry to support alarm monitoring and/or
recipe management.
Designed for easy maintenance and troubleshooting,
repairs are reduced to simply replacing modular, plug-in
components. The likelihood of faults and the time needed
to fix these errors is significantly reduced, eliminating the
need to rewire panels and devices. Now, errors can be
corrected by retyping the logic. Additionally, fault detec-
tion circuits and diagnostic indicators incorporated in
each major component can tell whether the component
is working properly. With the programming tool, any pro-
grammed logic can be viewed to see if inputs or outputs
are on or off.
Expanding PLC functionality with networking
Although PLCs opened the door for on-the-floor visual
communication, it was their integration with networking
devices that offered manufacturers a new level of visibility
and control by combining real-time Ethernet with visualiza-
tion, control, and communication capabilities.
To meet the growing operation needs of industrial auto-
mation, networks continue to expand, offering monitoring
and control capabilities in areas not previously possible.
Device networks are now using fieldbus-to-Ethernet
integration to develop enterprise-wide control networks.
Merging networking functionality with PLCs enables users
to off-load main processor tasks for distributed control in
the field, placing control-level devices closer to the action.
Additionally, by combining control
Courtesy: Turck
with distributed I/O, manufacturers
can lower their total cost of opera-
tion by streamlining data acquisition,
communication, and factory-wide
connectivity.
Networking: For PLCs to become
a networking tool, users must have
the necessary bandwidth that allows
real-time industrial Ethernet. Because
connection and communication
requirements are expanding, PLCs
must increase support for multiple
network technologies. While there is
no one-size-fits-all industrial network
for all of the advanced I/O solutions,
layer to the plant as needed by
accommodating multiple protocols.
Because network protocols add functionality, PLCs are
necessary components for driving and supporting these
additional functions.
Maintaining these industrial automation networks
continues to be a key component in ensuring these inte-
grated system continue functioning. A reliable network is
paramount. Therefore, maintaining network availability is
crucial. This requires the system to support the neces-
sary bandwidth and high data transmission rates to meet
application specifications, as well as data protection during
maintenance operations and fast recoveries if connection
failures occur.
Along with speed and availability, redundancy is impor-
tant for continued performance and reliability. Prolonged
periods of unplanned system downtime can become a
potential threat to plant productivity. However, redundancy
technologies not only provide msec-level network recovery,
but they can also substantially reduce deployment costs.
Distributed control: Using distributed control allows
parts of the automated system to be decentralized and
dispersed throughout the system. This means that certain
portions of the system are controlled by separate control-
lers located close to the area of direct control. This allows
multiple different form factors for a wide variety of appli-
cation requirements. Further, by spreading the I/O data
across the application as appropriate (either in-cabinet
or on-machine), manufacturers are able to reduce their
automation and control footprint by reducing the number of
necessary components.
Distributed control enables users to implement a flexible
modular design with the exact amount of I/O expansion
to be added when necessary, providing an inherent scal-
ability for fast, cost-effective updates for future expansion.
Distributed intelligence reduces any additional load on the
PLC, and also allows the system to accommodate future
functional requirements by enabling expansion while using
Applied Automation August 2013 • A5
 cover story
the same PLC to control auto-
mated applications. This means
users can enrich their systems by
expanding the size and functional
capabilities, and still standardize
on PLC systems.
During off-loading, some of
the control functions from the
main processor (either PLC or
PC-control) to the distributed
I/O—which are located either on-
machine or in-cabinet—reduce
network traffic. This occurs
because through the distributed
I/O, the main processor does not
need to make requests of the
remote I/O for status of inputs
or to initiate an output. The dis- Figure 3: Reduced hardware requirements, increased
tributed I/O system with control/ efficiency, and less waste are among the numerous
programmable functionality can benefits of implementing PLCs.
handle certain tasks, relegating
communications to supervisory or status data to the main
processor.
By enabling remote I/O configurations, manufacturers
can achieve high-level connectivity with only a few I/O
points required—even in widespread areas—providing a
cost-effective control solution for diverse industries and
applications. In large facilities where extensive monitoring
and control is necessary, it is not practical or cost-effective
to have a controller at each site. This would require a
tedious and expensive installation process that would
require each I/O point to be hardwired with cable running
over long distances. For example, remote I/O systems can
be used in acquiring data from remote plant or facility loca- wiring footprint while maintaining spare floor capacity. Using
tions. Information such as cycle times, counts, duration, or
events can be sent back to the PLC for maintenance and
management reporting. Additionally, hardwiring increases
the likelihood of errors, such as mis-wiring, which can
require excessive downtime to correct.
Advanced I/O capabilities: Networking technology has
expanded beyond standard digital input, digital output,
analog input, and analog output functionality. For example,
advanced I/O can include RFID technology, SSID for
motion and serial inputs, data logging, barcode, and 2D
matrix identification systems. Smarter, more advanced I/O
produces greater amounts of data, which integrated PLCs
must be able to manage.
Typical factory environments are looking for tighter
control of their manufacturing process, which results in a
need for more than discrete I/O. PLCs are configured with
advanced I/O such as analog signal processing, tempera-
ture, and RFID—all of which consume considerably more
bandwidth.
For example, PROFINET uses three different commu-
nication channels to exchange data with PLCs and other
devices. The standard TCP/IP channel is used for param-
A6 • August 2013 Applied Automation
eterization, configuration, and
Courtesy: Turck
acyclic read/write operations. The
real-time (RT) channel is used
for standard cyclic data transfer
and alarms. RT communica-
tions bypass the standard TCP/
IP interface to expedite the data
exchange with PLCs. The third
channel, isochronous real time, is
the high-speed channel used for
motion control applications.
Combining networking and
PLCs in the field
Remote I/O: The oil and gas
industry deals with hazardous
work environments and depends
on precision and reliability. For an
application that not only needs
dependable performance, but
also must adapt to changing requirements and increasing
demands, traditional control solutions are not ideal, and
instead require a modular solution that enables disas-
sembly and transportation. For oil and gas industries, it is
essential to use innovative connectivity solutions that allow
for communication across great distances without sacrific-
ing performance or being susceptible to environmental
elements. These demands require a reliable marriage of
control devices, such as PLCs, and networking protocols.
With these plants, the challenge is overcoming the wide-
spread design of the facility, which requires the network to
accommodate a large number of signals and still reduce the
distributed I/O systems that feature a hazardous area quick
disconnect wiring system provides a cost-effective answer
to a complex problem. The easy-to-configure systems
deliver remote I/O functionality for processing applications.
A single Ethernet cable is capable of handling high traffic
volume, transferring as many as 150 signals back to the
PLC from the various remote sections of the plant.
Using a sophisticated connector system to terminate
process instruments in the field consolidates those sig-
nals at a junction box for enhanced efficiency. Further,
by implementing twisted shielded pair cables for signal
transfer from the junction blocks to the PLC cabinet, and
armored single twisted pair cables to connect the junction
block to the instruments, there is no longer the need to run
all the cables back to the PLC individually. Instead, what
used to be eight wires has been combined into one single
cable. Because of the small size of the home run cable
receptacles, the size of the PLC cabinet, where all the sig-
nals eventually terminate, was also reduced. This results
in additional cost savings.
Additionally, to meet the individual needs of the oil and
gas market and its hazardous locations, these devices

Figure 4: In this coal processing plant example, each conveyor belt features its own control cabinet that incorporates connectors, motor-
circuit switches, and distributed I/O. The modular I/O stations transfer all the analog and digital signals to higher level PLCs that reflect
the transport system’s status.
must be properly mounted. Options are available that
include Ethernet protocols with Division 2/Zone 2 approval,
consolidating temperature, 4-20 mA, and discrete signals
and sending them at high speeds to the PLC.
Enhanced automation: A coal production plant has
extensive transportation systems that run through the
entire facility to transport the coal from its repository
to the coal mills. This transport system must be reli-
able at all times to promote continued plant productivity.
Consequently, automation is an obvious choice, but this
requires countless sensors and actuators to be installed
through the plant that must be managed and maintained.
To meet these specific demands, using a modern field-
bus system for the signal transmission between the PLC
and sensors/actuators can provide the necessary level of
automation, control, and durability. Implementing a proper
fieldbus system, one that features a modular design and
offers rugged protection, will not only provide interference-
free communication between all devices, but also a high
degree of data integrity, protection against vibration, and
extensive diagnostic functionality.
Consider an example of a coal plant that incorporates
two transport stations, two coal mills, and a coal bunker
from which the coal dust is blown into kilns. Among these
stations, coal is transported via multiple conveyor belts, so
it is crucial to keep detailed records as the product moves
through the various steps. Each conveyor belt features its
own control cabinet that incorporates connectors, motor-
circuit switches, and distributed I/O (see Figure 4). The
modular I/O stations transfer analog and digital signals to
higher level PLCs—which reflect the transport system’s
status including parameters such as rate of feed, offset,
distension, cracks, or fill level data—through a networking
protocol, such as DeviceNet. After evaluating the obtained
Courtesy: Turck
data, the PLC submits the plant’s status to the manage-
ment information system. All this control can be imple-
mented with just two fieldbus networks.
Manufacturers are assured of continuous transportation
of coal because of the reliable, efficient, and flexible field-
bus technology that provides error-proof production. Using
an IP67-rated fieldbus system, this solution meets the
high demands of the coal production industry, with simple
maintenance and fast diagnostics, combined with easy
and error-free installation and low wiring costs—ultimately,
ensuring efficient and safe plant operation—even in harsh
environments.
Conclusion
No two manufacturing environments are the same.
However, manufacturers share a common drive to produce
a high-quality product while maximizing efficiency, produc-
tivity, and profitability. The integration of control devices
such as PLCs and advanced enterprise networks offers a
proactive strategy for achieving these objectives.
Today’s networking technology delivers fast, secure, and
reliable factory-wide data transfer. PLCs deliver increased
diagnostic and communication functionality, providing an
intelligent, low-maintenance system that delivers signifi-
cant benefits. Now manufacturers can improve accuracy,
provide faster production speeds, and minimize errors, as
well as save on material and labor costs.
Randy Durick is director of the Networks and Interfaces
group and has 11 years of experience at Turck; Chris
Vitale is senior product manager, Networks and has 13
years of experience at Turck; and Matt Boudjouk is prod-
uct manager, Networks and Interfaces group and has five
years of experience at Turck.
Applied Automation August 2013 • A7
 Panel building

Optimizing control panel

design, construction
Modern control panel wiring methods can reduce the costs of manufacturing and ownership.

By Richard P. Chung, Eaton But how can a company gain a

Courtesy: Eaton
G
competitive advantage? The pri-
mary factors in establishing and
lobal pressures and maintaining a first-mover advantage
decreased time-to-mar- are decreasing time-to-market and
ket challenge manufac- getting early feedback from custom-
turers to embrace Lean ers/end users on prototype designs.
concepts and use inno- For example, the U.S. automotive
vations to maximize their competi- market is experiencing a growth
tive effectiveness. Recent technol- period and is faced with the chal-
ogy advancements intended to mod- lenge of reducing time-to-market for
ernize conventional control panel new vehicle programs. What used
wiring are transforming how panels to take 48 to 60 months from start
are designed, built, commissioned, of program to start of production is
and maintained (see Figure 1). compressed to a 24- to 30-month
Every year, the bar is raised on cycle. In other words, machinery
competitiveness. New technolo- Figure 1: Recent control panel innovations offer original equipment manufacturers
gies, innovations, and more effec- significant improvements over conventional (MOEMs) that used to have 40 to
tive manufacturing practices propel control panel wiring methods, which can reduce 60 weeks of lead time from contract
us to higher levels of productivity. the costs of manufacturing and ownership. to delivery are now challenged
The U.S. Bureau of Labor Statistics to deliver equipment in 20 to 30
reported that labor productivity weeks instead.
increased in 83% of the 86 manufacturing industries stud-
ied in 2010, with 57% of these industries posting produc- Increasing productivity
tivity gains of 6.1% or more as opposed to 2009, when The first step for increasing productivity for control
40% of industries recorded productivity losses. panel building operations is to understand how costs
It is no surprise then that productivity is among the top are allocated to design, engineering, material, assembly,
five priorities for companies. The CEO Institute reports that documentation, quality control testing, and commission-
the top five issues that keep CEOs awake at night include: ing. Material costs can range from 35% to 65% while
1. Improving productivity engineering, testing, and assembly costs make up the dif-
2. Reducing costs ference. Also, the costs for on-site installation and com-
3. Achieving operational efficiency missioning must be considered for system integration or
4. Managing increasing competition turnkey operations.
5. Achieving top line growth. Further, often-ignored, and hardly documented over-
head costs are absorbed—although they may actually
So how do engineering managers translate these direc- pertain to specific projects. Some of these costs relate
tives to drive productivity and competiveness? Instilling a to preengineering, preliminary designs, and/or post order
broader view of initiatives and looking at the total cost of service help or troubleshooting at a customer’s request.
ownership over the investment cycle—instead of the initial Although considered good will, the time required increas-
project cost—is crucial. Driving standardization and effi- es the cost of doing business. Increasingly, MOEMs are
ciency wherever possible also helps. Increasing productiv- discovering that including some level of machine- and
ity is no longer a voluntary objective; it is required for busi- control-panel diagnostics allows them to help customers
ness survival because productivity gains help to insulate troubleshoot systems themselves—with a little guidance
businesses from negative economic impacts. via a conference call instead of making a costly site visit.

A8 • August 2013 Applied Automation

 Time, material savings mean cost savings
M any people say, “Time is money.” However, mate-
rial is too. When it comes to engineering, assem-
bling, and testing control panels, reducing either time
Time reduction example
Conventional
Device-level
Savings
wiring system
or materials (or both) can reduce costs significantly.
Wiring time 269 min 41 min 85%
Here are two examples that illustrate how reducing
Engineering time 115 min 35 min 70%
time and materials can also reduce costs.
In the time reduction example, the estimated time Testing time 46 min 4 min 90%
to wire motor starters, contactors, and pilot devices
is 4 hours and 29 minutes. However, the estimate Material cost example
is only 41 minutes if a device-level wiring system is Flat cable Control wiring #14 AWG
used—an 85% reduction in wiring time. Engineering
Length (in miles) 0.45 7.83
and testing times were also reduced.
Length (in feet) 2,362.00 41,339.00
In the material reduction example, an installation
that consisted of 1,600 motor starters would have Cost per foot $0.61 $0.14
required 7.83 miles of control wiring. However, by Total cost $1,441.00 $5787.00
using a device-level wiring system, only 0.45 mile of
flat cable was used. Calculating the material cost of multitude of control wiring connections. This type of
each method using $0.61/ft for flat cable and $0.14 control system can also connect electronic motor
for #14 AWG, the device-level wiring system saved starters to the system, which allows motor current
more than $4,300. In addition, the calculated savings and other loads to be monitored without having to
for wiring/assembly time was 22 man-days. add current transformers or analog input cards to
Another significant benefit is the device-level the PLC. This feature could enable a higher level
wiring network allowed the system to be installed of predictive data monitoring that was prohibitively
and commissioned without having to ring out a expensive in the past.
Courtesy: Eaton

Courtesy: Eaton

Figure 2: Additional control panel construction time is required
when wiring is bundled to door-mounted devices because wires
must not restrict opening and closing the door.
Finding cost-reduction opportunities
But what is to be done after the best component price
is negotiated and the smallest footprint and enclosure
size is established? Further cost-reduction opportunities
are limited by conventional hardwired control panels. With
material costs a relative constant, the real opportunities for
cost reduction exist in reducing control-panel engineering,
testing, and assembly time. Perhaps creating a standard-
Figure 3: Typically, control panels change over time to accommo-
date wire tracing, configuration/design modifications, the addition
or removal of control or electrical components, or tapping into the
control power supply.
ized layout or replacing hardwired pushbuttons with a
touchscreen on a control network can minimize engineer-
ing time. For example, it is typically advantageous to use
a touchscreen in designs with 10 or more pushbuttons.
Additionally, even using spring-cage terminals instead of
standard screw terminations can reduce wiring time by
about 15%.

Applied Automation August 2013 • A9

 PANEL BUILDING
Using wiring harnesses can speed assembly time and
help eliminate wiring errors. However, this approach is
practical only when constructing significant quantities of
the same control panel. Automating mundane tasks such
as wire stripping and marking can improve quality and
consistency while saving time. However, this approach
also requires a significant amount of repetitive panels to
justify the payback. Establishing point-to-point wiring prac-
tices among assemblers can also help reduce testing and/
or troubleshooting time. While functional testing typically
reduces the time required to check point-to-point wiring,
when something goes wrong, it can still take an unpre-
dictable—and possibly an inordinate—amount of time to
locate and correct faults.
Challenges with hardwired systems
Hardwired control panels continue to serve the automa-
tion/control industry very well. However, they present cer-
tain challenges because of the intensive labor required to:
 Cut individual control wires to the proper lengths
 Strip the insulation
 Add wire identification markers
 Add ferrules at the ends of wires.
A simple control panel with a PLC and about 100 I/O
points typically requires a wiring schedule or chart to
instruct the assembler how to connect the PLC’s I/O mod-
ules to the corresponding contactor, pushbutton terminals,
sensors, or other field devices. When more than one panel
is required, a wiring schedule is an efficient way to provide
wiring instructions and to ensure consistency. However, it
requires engineering time to create the wiring schedule.
A10 • August 2013 Applied Automation
Figure 4: Before industrial
Courtesy: Eaton
control networks or fieldbuses,
control panel connections
were hardwired using point-
to-point wiring inside cabinets
and home-run wiring to and
from remote cabinets.
Also, with numerous wires
in close proximity, wiring
errors are likely. A wrong
connection typically implies
that there are multiple wir-
ing errors.
More often, a detailed
schematic diagram is
used, which requires the
assembler to interpret the
diagram and keep track of
all the wiring by highlight-
ing each wired connection
as it is physically wired.
This is a tedious but
essential practice that consumes time but minimizes the
chance of not making a wired connection—which would
be more troublesome to troubleshoot during the func-
tional test stage.
When wiring is bundled to door-mounted devices, addi-
tional time is required to properly dress and bundle the
wires in a way that does not restrict opening and clos-
ing the door, or does not damage the wiring bundle (see
Figure 2). When wiring to small saddle-clamp-type connec-
tors on pushbutton contact blocks, special steps must be
taken to ensure that wires are inserted on the correct side
of the saddle clamp, and to ensure proper electrical con-
nections are made. Visibility and access become increas-
ingly restrictive as component layout density grows or as
pilot devices are added to the layout matrix.
Finally, after the panel is wired, last-minute engineering/
design changes may be required. There may be control
program modifications, or the customer may wish to add
(or remove) components, features, or options. These
changes must be accommodated before the control panels
leave the shop.
After the control panel is installed on-site, other chal-
lenges take over. Eventually, wiring duct covers may
be removed to allow technicians to trace wires, control
program modifications may be made, field devices may
be installed requiring additional I/O wiring, or an added
device/component may require wiring to be routed from
the control power supply (see Figure 3).
Wiring, layout, and control program changes usually go
undocumented. Typically, drawings are seldom updated
and control scheme and programming changes are not
recorded. However, depending on the business arrange-
Figure 5: Device-level wiring
systems use smart modules
that connect standard motor
control components via flat
cable to a gateway module,
which connects to a standard
fieldbus on the PLC’s CPU.
ment, the machine builder
may still be responsible for
the control panel, regard-
less of the ad hoc changes
that may occur in the field.
Improving control-
panel connection
methods
How would reducing the
number of point-to-point
wires in a control cabinet
affect productivity? Less
wiring translates into less assembly time, fewer chances of
making mistakes, less time required to check and test wir-
ing connections, no time needed to create a wiring sched-
ule, and more available control cabinet space.
Remember when the connections in the control panel
were hardwired—before industrial control networks or
fieldbuses (see Figure 4)? Remember when the wiring
between control panels consisted of home-run wiring to
the main controller and I/O modules? Fieldbuses and
remote I/O eliminated home-run wiring, which marked a
major productivity shift in on-site control wiring and system
installations.
Although the various fieldbuses greatly improved system
installation productivity, point-to-point wiring is still required
within the cabinet to connect control components to I/O
modules. While the elimination of home-run wiring to and
from field devices has greatly improved productivity, that
level of productivity has not been available for wiring within
the control cabinet.
What if control components could be connected to the
PLC’s CPU without point-to-point wiring or without the
need for some of the I/O wiring? What if I/O could be dis-
tributed to the component level using an approach that is
economically feasible, is functionally equivalent to point-
to-point wiring (or better), and is well suited for the dense
arrangement of control components normally found in a
control panel?
Consider a control panel wiring method that could:
 Connect standard motor-control components
 Eliminate most hardwiring
 Accelerate the engineering, assembly, testing, and
commissioning processes
 Reduce control-cabinet space requirements
 Connect to industry-standard networks and fieldbuses.
Courtesy: Eaton
Device-level wiring systems that use smart modules,
which attach to standard motor control components, such
as contactors, motor starters, and other control circuit
devices, are now available. These smart modules con-
nect via flat cable to a gateway module, which connects
to a standard fieldbus on the PLC’s CPU (see Figure 5).
Device-level wiring systems that incorporate a power sup-
ply can help eliminate most of the control wiring from the
PLC’s I/O modules to motor starters and control circuit
devices. The I/O typically associated with controlling motor
starters and control circuit devices can also be eliminated.
To understand the productivity, reliability, and eco-
nomic advantages of using a smart-module-type device-
level wiring system, compare its advantages to those of
a conventionally wired control panel. A wiring duct in a
typical conventionally wired panel with numerous control
wires can be replaced with a flat multiconductor cable
that serially connects the components (see Figure 6).
Many of the PLC’s I/O modules have been eliminated,
which increases available panel space. Saving panel
space can significantly reduce material costs when
stainless-steel enclosures are required. Panel assembly
time is also significantly reduced, and testing time is vir-
tually eliminated because there is only one flat cable to
check. Diagnostic LEDs on the communication modules
indicate network status, which further accelerates test-
ing and commissioning.
From a maintenance perspective, a device-level wir-
ing system has fewer connections that must be checked
periodically for termination integrity. Dual-color LEDs on
the wiring system’s modules simplify troubleshooting. The
modules also provide access to byte-level network sig-
nals to further aid diagnostic and troubleshooting efforts.
Because a single flat cable connects control compo-
Applied Automation August 2013 • A11
 Panel building

nents, field wiring modifications completed panel.

are less likely to occur. However, if
and when they do, their presence
is evident. This helps to protect the
machine builder’s intellectual prop-
erty, and to preserve the original
craftsmanship and quality of the
Courtesy: Eaton
Device-level wiring systems reduce
engineering, design, assembly, and
wiring time (see “Time, material sav-
ings mean cost savings”). They also
simplify control connections, extend
diagnostic capabilities to the device

Figure 6: Device-level wiring systems use

flat multiconductor cables to connect com-
ponents, replacing bulky wiring ducts found
in conventionally wired control panels.

level, and increase the reliability, con-

sistency, and flexibility of the control
scheme.

Let ProSoft Technology’s Control-panel connectivity—

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Whether connecting to dedicated/
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Legacy system networks include: control panel engineering, construc-
DH+™ tion, testing, and commissioning
Honeywell IPC-620 are available now. At last, there is a
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Fisher PROVOX Control I/O outs, allowing them to design modu-
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Richard Chung is a product man-

ager at Eaton. He has more than 25
Where Automation Connects
years of experience in the control and
+1-661-716-5100 automation industry.
www.prosoft-technology.com/migration
A S I A PA C I F I C | A F R I C A | E U R O P E | M I D D L E E A S T | L AT I N A M E R I C A | N O R T H A M E R I C A
A12 • August 2013 Applied Automation
 VFD reDunDAncy

VFD bypasses and backups:

Which should you use?
Advanced motor protection and consistent energy savings are
possible with true redundancy.

By Tommy Trullinger Traditional bypass

O
C er u s Indust r ial Inc., Hi l l sboro, O re . A traditional bypass consists of a separate motor
starter, mechanically interlocked with its companion
riginally introduced as an efficient and effec- VFD output contactor in a way that allows only the VFD
tive way to reduce energy consumption or the bypass to operate the motor at any given time.
by allowing motors to be run at different Most traditional bypasses default to manual opera-
speeds, VFDs have become common- tion to engage the bypass. In other words, someone
place in the HVAC industry. While there is must manually turn on the bypass in the event that the
no question that VFD technology helps save energy, VFD fails. A VFD fault relay can be used to start the
unfortunately it was somewhat unreliable in the early bypass automatically based on a VFD fault, but only if
years. The VFD bypass was introduced to ease con- the VFD is not damaged. Traditional bypasses are also
cerns around reliability, and it played a significant role available in 2- or 3-contactor variations. A 3-contactor
in the rise of VFD usage. bypass introduces an additional contactor or a VFD
A traditional mechanical isolation switch that disconnects
bypass acts as a backup sys- the VFD from power supply. This
tem to ensure equipment stays A traditional mechanical enables an electrician to completely
operational when or if a VFD remove the VFD while the applica-
fails. A bypass is essentially a bypass acts as a backup tion is running in bypass mode.
motor starter that is built into However, this is not recommended
(around) the VFD to maintain full
system to ensure equip- as it sets up the electrician to work
voltage (across the line) control ment stays operational in close proximity to high-voltage
of the application. The backup wiring. A 2-contactor bypass is suf-
allows the application to run at when or if a VFD fails. ficient for most applications requir-
full speed until the problem with ing a bypass and does not provide
the VFD can be addressed. a complete VFD isolation. Also,
The bypass, along with the VFD, have become keep in mind that local codes may restrict the actual
staples of the typical HVAC configuration, and over the configuration.
years have made their way into almost all consulting
engineers’ specifications. The problem is that the major- Common features of a traditional bypass include:
ity of specifications today still hang on to the idea that n Available in 2- or 3-contactor variations
bypasses are always needed. VFDs, like most electron- n Disconnect is typically integral
ics, have improved dramatically since they were first n “Hand, Off, Auto” switch for VFD and bypass
invented. They’re more reliable now and have extremely n “VFD/Off/Bypass” switch
low failure rates. They’re also much more compact and n Manual bypass standard (auto relay available)
economical than in years past. n Thermal overload protection.
Recently, VFD manufacturers have developed new
and improved bypasses, as well as motor drive pack- The traditional bypass is readily available. Other
ages with full redundant capabilities. Opinions abound advantages are that it is inexpensive in comparison to
about which backup or bypass should be used for other backups, allows for BAS control, and is extremely
various HVAC applications, but there are few guides reliable.
that provide a definitive answer. To better understand On the downside, a traditional bypass offers no
the selection process, it’s important to first look at the advanced motor protection, needs relays for automatic
pros and cons of the various bypasses and backups control, and has no soft-start capability. Communication
available. to the BAS is limited, communicating status/fault only.

Applied Automation August 2013 • A13

 VFD reDunDancy

All energy savings are lost and consumption is not mon- becoming more competitive, it’s only a matter of time
itored in bypass mode. Finally, the traditional bypass before bypasses fade away as a viable choice, and dual
offers 60 Hz operation only. VFD systems become the standard for critical applica-
tions. Most VFD manufacturers offer some type of pack-
Electronic (smart) bypass aged redundant drive systems as part of their custom
The electronic bypass was recently introduced to offering. This means they must be approached on a job-
address a number of concerns with built-in logic and by-job basis.
advanced motor protection. This microprocessor-based It’s important to understand that these packages
bypass offers advanced features require a level of customization
such as protection from phase because they consist of more
loss, ground fault, over/under- Pros of redundant VFDs than just two VFDs. To maintain
voltage, and over/under power. true redundancy, extra power and
These protection features go far include full redundancy, full control circuitry must be added.
beyond what a traditional thermal The standby VFD must be iso-
overload provides. Electronic
control with backup VFD, lated from power while the primary
bypasses also typically include a and advanced motor pro- VFD is running to ensure both
provision for a BAS to communi- primary and backup VFDs aren’t
cate directly to the bypass in the tection all the time. damaged in the event of a power
event of VFD failure. This should surge or spike. To isolate the
be coordinated with the BAS soft- VFDs, mechanically interlocked
ware manufacturer. The electronic bypass allows users input contactors should be added. Provisions must also
to select certain conditions in which they want the be made to ensure that the backup VFD doesn’t sit for
bypass to start automatically, and incorporates other extended periods without being periodically powered
features that traditionally would only be supported by up. VFD dc bus capacitors have a shelf life and can
the VFD (fault logging, delays, etc.). There are also degrade without periodic charge cycles. The control
electronic bypasses on the market that integrate full system should provide scheduled alternation or charge
ANSI-grade power metering, and BACnet or other com- cycles for standby VFDs. The downside of the added
munications interfaces to allow for seamless control power and control components is unfortunately an addi-
and communications whether in VFD or bypass mode. tional cost.
Pros of redundant VFDs include full redundancy, full
Common features of an electronic bypass include: control with backup VFD, and advanced motor protec-
n Keypad with LED indication tion all the time. They provide consistent energy savings
n Communication card because VFD operation is maintained even when one
n Advanced motor protection fails. However, they are more expensive than traditional
n Common start/stop terminals and electronic bypasses and have a larger footprint.
n Fireman’s override
n Bypass fault logging Selection guide
n Selectable auto bypass When using a value engineering approach, consid-
n Power failure modes. erations must be made to select the proper backup for
various HVAC applications. From a purely economic
On the positive side, electronic bypasses offer fea- standpoint, this means in many cases the designer/
tures such as advanced motor protection, BAS commu- specifier should aim to limit the amount of downtime
nications, logic to assist with troubleshooting, flexible rather than eliminate it completely for noncritical appli-
control features, and compact physical size. But these cations. In other words, the proper backup for some
bypasses come at a higher cost. They also lack soft- applications may be no backup at all. A VFD with a dis-
start capabilities and motor speed control in bypass connect makes sense for noncritical applications as long
(60 Hz only). as steps are taken to ensure downtime is limited in the
event of a failure. One approach would be to purchase
Redundant drives a spare VFD in each frame size to keep on hand. This
Redundant VFDs are the logical next step in con- could easily be done with the funds saved from elimi-
trol for critical applications. They work on the principle nating the bypass on all noncritical applications. Those
that if one VFD fails, full control and protection are savings can also be passed on to cover the cost of
maintained by a second VFD that automatically takes redundant VFDs for critical applications.
over. Redundant VFDs are not a new concept; the idea The following is a series of questions to ask when
has been around for years, but only recently has this making backup selections:
concept become cost-effective. With the VFD market 1. Is this a critical application (clean room, hospital

A14 • August 2013 Applied Automation

operating room or ICU, data center, etc.)? If yes, specify
redundant VFDs. If no, move to Question 2.
2. Is this noncritical application tied to fire alarm for
smoke control?
If yes, specify smart bypass (or traditional bypass with
provision for fireman’s override). If no, specify a VFD
with disconnect only.
Bypass should not be used in some situations. For
example, do not use bypass on supply fans. Doing so
doesn’t make sense for system control, and doesn’t
make sense economically. If the VFD is flipped to
bypass, damage can be caused due to over-pressur-
ization of ductwork. This is especially true for variable
air volume systems. If balanced at 50 Hz, for example,
major damage can occur if the VFD is bypassed at 60
Hz. If a bypass must be used, provisions should be in
place to prevent damage in the bypass mode. Controls
should ensure inline dampers are fully open, and a
high-pressure limit switch should be added to cut off
the VFD before damage occurs. If there is a return
exhaust fan, this must be controlled in synchronization
with the supply fan.
Bypass should not be used on applications running
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at frequencies over 60 Hz. Many of today’s air handlers
are running over 60 Hz. Switching to bypass on these
systems will limit them to 60 Hz, which won’t necessarily
cause damage, but under-pressurization and poor per-
formance may occur. In these instances, a better option
would be a redundant VFD system. It’s possible to use
redundant VFDs sized for multiple loads on fan-array-
type applications. This way, full control is maintained if
the primary VFD fails. In this type of installation, each
motor must be individually protected by a separate over-
load, and the VFD overload must be disabled.
Choosing among the many options for backups,
bypasses, and motor drive packages can be confus-
ing. To ease the selection process, remember to first
carefully consider the advantages and disadvantages
of each.
Tommy Trullinger, HVAC product manager, has been
with Cerus Industrial for three years, first as an appli-
cation consultant and now product manager. He is a
graduate of Concordia University in Portland Ore., and
an affiliate member of ASHRAE.
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 ©2013 Siemens Industry, Inc.
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Answers for industry.