Integrated, Intelligent

Motor Control Centers

Integrated, Intelligent Motor Control Centers

Industry Overview
The goals for any commercial or industrial process are simple:
minimize overall costs and enhance productivity. To achieve these
goals, processes require better monitoring, less downtime, and faster
maintenance. Obtaining real-time process information requires
integrating hardware, software, and communications. Communication
and advanced sensing technologies now exist at the device level, and
recent enhancements make a completely integrated solution both
usable and affordable.
Motor control centers (MCCs) occupy a prominent role in control
schemes, housing a comprehensive array of control and monitoring
devices. MCCs have moved rapidly to include the latest component
technologies and integrating these advanced technologies presents a
major opportunity to transform islands of data into useful
information that minimizes downtime. This paper focuses on
technology integration methods in MCCs, and quantifying associated
costs and benefits.

Historical Progression
MCC Benefits

The benefits of MCCs are well documented and proven by the

approximate $1.5 billion USD global market. These benefits include:

Quicker installation at a lower cost with its own power bus and
factory-wired and tested units, field wiring and testing are
minimized.

Saves floor space compared to individually mounting the same

devices

Reduced planning and downtime - standardized sections and

units simplify design and training; plug-in units can be easily
replaced and rearranged

Expandability sections and units can be added to existing

MCCs

Increased level of safety fault containment is part of MCC

design, and units can be easily unplugged to service at a
workbench, away from hazardous voltages

Faster delivery entire system arrives ready to install as a single

entity, with no additional design or components to coordinate

Serviceable with power ON at adjacent starters the inherent

isolation of MCC units makes it possible to work on a given unit
without de-energizing any adjacent units, and still conform to
code and OSHA requirements

Integrated, Intelligent Motor Control Centers

Traditional Electromechanical
Components

Traditionally, MCCs contained only electromechanical components

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

Solid-State Components

Advances in solid-state technology ushered in a revolution in control

systems with intelligent devices that could be programmed to do more
than just turn a motor on and off. These smart components found a
warm reception in MCCs, and soon AC drives, soft starters,
programmable logic controllers (PLCs), and electronic overload
relays were standard offerings in MCC units. Integration was
accomplished through hard wiring to an I/O Chassis.
For a detailed discussion of issues and costs associated with
interwiring in MCCs, refer to Appendix A.

Networked Components

The advent of device-level communication networks brought new

possibilities for advanced monitoring, control, and diagnostics. These
networks also greatly simplified wiring, eliminating the bundles of
control interwiring and corresponding complex interwiring diagrams.
Although early MCC network communication brought benefits, there
were also some challenges:

Reliability and flexibility shortcomings in the daisy chain

drop-line architecture connecting units to the main trunk line.
Adding new units or accidental breaks in the chain affected any
downstream units in that connection, potentially shutting down
equipment.

Safeguarding exposed trunk line and drop line cables in the

wireways, when pulling and installing other power cables.

Establishing initial network communications with MCC unit

devices.

Separating power and communication cables to meet code

requirements. In confined wireways, adequate separation was
difficult at best.

Integrated, Intelligent Motor Control Centers

Integrated, Intelligent MCC

The network communication challenges revealed a need to integrate

the three major system components: the communications, the
hardware, and the software.
These next generation, integrated, intelligent MCCs are current
technology. The design streamlines installation, set-up, and changes;
delivers real-time monitoring of the MCC; and easily integrates into a
facility-wide network.
The questions for todays users are:

What is the extra cost to buy an integrated, intelligent MCC?

What are the real advantages and benefits for my facility vs.
potential headaches and extra cost?

The following section highlights some issues that a user should

consider.

Key Issues To Consider When Evaluating an

Integrated, Intelligent MCC
Different Elements vs. a
Standard MCC

An integrated, intelligent MCC will contain some different elements

in both the sections and the units, plus software. These can be
categorized as: the built-in communication media, intelligent motor
control components, and MCC monitoring software. Keep in mind
that an MCC may not be an integrated, intelligent MCC, just because
it includes these elements. The early versions of MCCs with
communication networks contained variations of these elements. The
major distinction is that there was not a harmonized design that
deliberately integrated the communication network, hardware, and
software.
A standard MCC ships without interwiring, and requires extensive
interwiring, documenting, and testing in the field. The integrated,
intelligent MCC arrives ready to install, pre-tested and preconfigured; the communication cables are installed and tested, the
intelligent devices are pre-programmed (with baud rate, node number,
trip current, etc.), and the software screens are pre-configured.
The following sections review important considerations for the
elements outlined above, and provide a framework for evaluating
potential integrated, intelligent MCC offerings.

Integrated, Intelligent Motor Control Centers

Built-in Communication
Network

The communication network needs to be analyzed with respect to

both the network performance and the physical construction.

Proven, open communication network The trend toward open

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

DeviceNet

Throughput

Up to 500 kbps communication rate

Cost per node

Low node cost, due to high

production volume of controller area
network (CAN) chips

Immunity to typical MCC

noise

Proven noise immunity (refer to

Publication 1485-WP001A-US-P)

Cable rated for use adjacent

to power wiring

Both flat and round Class 1, 8A,

600V cabling available

Accepted by a wide range of

suppliers and users

DeviceNet products are offered by

over 300 suppliers, with over half a
million installed nodes

Optimized Physical Construction The obvious approach for

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

Integrated, Intelligent Motor Control Centers

Droplines behind barriers

or vertical wireway

Trunkline behind
barriers

Intelligent Motor Control

Components

Individual network
ports accessible in
vertical wireway

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

Intelligent overload relays The most common device in the

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

Integrated, Intelligent Motor Control Centers

Protective functions thermal overload, underload, jam,

current imbalance, stall, phase loss, zero sequence ground
fault, and PTC thermistor input.
Programmable parameters for the protective functions - trip
level, warning level, time delay, and inhibit window. The
ability to program these features avoids the nuisance trips
that often led to users disabling protective functions.
Warning alarms alert users to a potential trip, and allow
actions to avert impending downtime. Time delays and
inhibit windows allow recognition of abnormal current loads
(e.g. extended starting times with high currents), without
nuisance tripping.
Current Monitoring phase, average, full load, ground fault,
imbalance percent, and percent thermal capacity used are
important monitoring features.
Diagnostics device, warning, and trip status; time to
overload trip; history of last five trips; time to reset.

MCC Monitoring Software

Miniature I/O module for non-intelligent units Traditional

electromechanical starters and feeder disconnects have no means
to communicate with networks. Wiring to a distant I/O chassis is
not the ideal solution. The preferable solution is an I/O module
within the unit small enough so that the MCC unit size is not
altered - to link the device and the network. The I/O module
should have an adequate number of inputs and outputs, according
to the unit functions. For a starter, four inputs and two outputs
satisfy 99% of applications.

Network communication interface module with input points

Intelligent devices often require an external communication
module. Ideally, this module should contain input points (again,
to eliminate wiring to a distant I/O chassis). Four inputs are
sufficient for most applications.

Integrated, intelligent MCCs have dedicated software that delivers a

window into the motor control center and related equipment. MCC
software eliminates creating costly customized MCC screens within
operator interface software, yielding a plug and play solution
usable by computer novices. The following checklist identifies
benchmarks for integrated, intelligent MCC software.

Operates in a familiar environment The software will be

easiest to use if it behaves according to known operating
environments, e.g. Windows.

Includes unique MCC documentation to initialize screens

Every MCC is unique. The application program, upon
installation, should access specific information to generate
screens containing data pertinent to that MCC.

Integrated, Intelligent Motor Control Centers

Initiates network communication Establishing devices as

recognized entities on a network can be the most time-consuming
step. In the optimal situation, the MCC manufacturer downloads
user-specific information like node addresses (per user
specification or a standard scheme), and baud rate, then tests the
entire system for accurate functions and communication. Upon
installing the MCC and software, the user only needs to sit back
and let the software poll the pre-configured devices to match the
device information with the user database.

Displays pre-configured screens showing most common

parameters Intelligent MCC software can access the users
specific data files and build the corresponding screens. The
following pre-configured software screens are useful:
MCC line-up (elevation) view Realistic dynamic display
that shows unit type, nameplate information, and status of
units.
Unit View Supplies dynamic information about the unit
and network device. Parameters of greatest interest are
already shown, and can be changed if necessary. Data can be
displayed digitally, on meters or trend graphs.
Event Logging Automatically logs preset and user-defined
faults and warnings, and accepts manual entries such as
maintenance activities and equipment updates.
Spreadsheet View Ideal for viewing the most information
at a glance. Sorting and filtering capabilities help users
organize pertinent data.

Includes all user-specific documentation A comprehensive

documentation database minimizes frustration and downtime
experienced while trying to locate misplaced documentation.
Valuable documentation components are:
Unit wiring diagrams
As-built drawings of the MCC line-up
Product user manuals
Spare parts list
Databases should allow users to add and change information,
especially wiring diagrams.

Can be accessed at any network level The user should be able

to view the MCC by plugging into any network level, such as
DeviceNet, ControlNet, or Ethernet. This feature gives the user
flexibility to locate the software on a maintenance laptop, in a
control room, or at an engineers desk.

Integrated, Intelligent Motor Control Centers

System Design and Testing

Component and systems tests should have been performed, with

demonstrated compliance results readily available. The following
tests assure that integrated, intelligent MCCs will function as
expected and required.

Design verification tools - Designing networks requires a

thorough understanding of the associated rules and parameters. A
software design tool should be available to verify if critical
network and design parameters have been met. Such software
simplifies the entire design, order, and installation process.

Electrical and environmental testing - a full battery of tests, both

individual components and when installed as a system include.
Noise immunity
IEEE qualification tests
Showering arc
Electric drill
Walkie-talkie
Overload jogging
Short Circuit
UL component and cable qualification
Shock and vibration
Seismic

Completed system testing verify:

Cable system integrity
DeviceNet module communication
Network baud rate and node numbers
Software content

10

Integrated, Intelligent Motor Control Centers

Efficiently handles MCC changes and upgrades MCCs often

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

Integrated, Intelligent Motor Control Centers

11

Cost Comparison
How much extra does an integrated, intelligent MCC cost? The
answer requires careful definition of MCC equipment to be compared
in the cost analysis. For example, it is not logical to compare a
standard unwired MCC to an integrated, intelligent MCC.
An appropriate analysis compares an MCC interwired with an I/O
chassis, to an integrated, intelligent MCC. Both are complete
interwired and tested systems, and both provide basic monitoring and
control.
The study evaluates costs for three versions of MCCs: an MCC
interwired to a larger, advanced function PLC I/O chassis; an MCC
interwired to a smaller, basic function PLC I/O chassis; and an MCC
with DeviceNet cabling and necessary DeviceNet hardware. Two
versions of PLCs were used to account for size, function, and cost
differences over a wide scope of PLC offerings. The study consists of
two parts: a variable size analysis that compares costs as the number
of units and sections increases (from 10 starters to 50 starters) with
varying numbers of inputs; and a specific comparison of costs for a
sample representative MCC line-up (eight sections). For simplicity,
the variable size analysis includes one version of a full-voltage
non-reversing (FVNR) starter unit added repeatedly. The sample
representative MCC allows a check on the reasonableness of the
variable size analysis, and is a more realistic representation of a
typical MCC line-up.

General Assumptions for All Cases

The study only includes actual manufacturer equipment and

wiring costs. Any charges associated with pre-order and postshipment activities are assumed common and equal, and are
excluded.

The study does not include costs for mechanical installation of

MCCs.

Common costs for all three methods are not included, e.g. wiring
diagrams, any engineering and drafting charges, network
software, PLC programming software, and any dedicated
equipment software. For the study, these costs are assumed to be
common and equal.

Sections are 20 (508 mm) wide, 15 (381 mm) deep, NEMA

Type 1, with 800 ampere copper main power bus with tin plating,
and a x 1 horizontal ground bus.

FVNR starter units contain a circuit breaker disconnect with an

internal normally open auxiliary contact; transformer control; red
and green pilot lights; solid-state overload relay; and one
normally open and one normally closed auxiliary contact
mounted on the starter.

12

Integrated, Intelligent Motor Control Centers

Case 1
Class II MCC with a Larger,
Advanced Function PLC I/O
Chassis

Case 2
Class II MCC with a Smaller,
Basic Function PLC I/O Chassis

Case 3
MCC with DeviceNet Cabling

Specific Case Assumptions

PLC unit has an eight-slot chassis, power supply, distributed I/O

adapter module, and modules included for inputs and outputs. For
the trend comparison, when the eight slots are exceeded, another
PLC unit is added.

All inputs and outputs are isolated in accordance with transformer

control in the units.

16-input and 16-output modules are included, reflecting typical

user practices. For the trend comparison, when the 16 inputs or
outputs are exceeded, an additional module is added.

Specific Case Assumptions

PLC unit has a seven-slot chassis, power supply, distributed I/O

adapter module, and modules included for inputs and outputs. For
the trend comparison, when the seven slots are exceeded, another
PLC unit is added.

All inputs and outputs are isolated in accordance with transformer

control in the units.

8-input and 8-output modules are included, reflecting typical user

practices. For the trend comparison, when the eight inputs or
outputs are exceeded, an additional module is added.

Specific Case Assumptions

DeviceNet cabling is 8 ampere, 600 Volt, Class 1, behind barriers,

with connectors in the vertical wireway.

DeviceNet nodes are configured.

Every FVNR starter unit contains a miniature I/O module with 4

inputs and 2 outputs.

Linking device permits seamless communications from

ControlNet to DeviceNet. No PLC unit is required.

8 ampere DeviceNet power supply included.

Integrated, Intelligent Motor Control Centers

13

Variable Size Analysis

Additional Assumptions

The process to determine comparative costs consists of: Assume

an initial line-up containing ten (10) size 1 full-voltage nonreversing starter units in sections, and a PLC unit to
accommodate inputs and outputs. Add Size 1 FVNR starter units
individually up to a total of 50. Include extra PLC units as
required for inputs and outputs. Provide adequate sections to
house all units.

Six (6) size 1 FVNR starter units per section.

One output required for each coil.

Three permutations were performed for the inputs, using two,

three, and four inputs. Inputs are typically used to monitor:
Contactor
Overload relay
Unit disconnect switch
Hand-off-auto selector switch

The following graphs illustrate the comparative costs for DeviceNet

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

14

Integrated, Intelligent Motor Control Centers

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

$150,000

Smaller jump when

another section is added

$130,000

MCC List Price

$110,000

$90,000

$70,000

Class II I/O 2 Inputs/Unit

Class II I/O 3 Inputs/Unit

Large jump when

another PLC chassis
is added

$50,000

Class II I/O 4 Inputs/Unit

DeviceNet w/4 Inputs/Unit

$30,000
10

12

14

16

18

20

22

24

26

28

30 32

34

36

38

Total Number of FVNR Starter Units

40

42

44

46

48

50

Integrated, Intelligent Motor Control Centers

15

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

$170,000

$150,000

Smaller jump when

another section is added

MCC List Price

$130,000

$110,000

$90,000

$70,000

Class II I/O 2 Inputs/Unit

Class II I/O 3 Inputs/Unit
$50,000

Class II I/O 4 Inputs/Unit

Large jump when

another PLC chassis
is added

$30,000
10

12

14

16

18

20

22

24

26

28

30

32

34

DeviceNet w/4 Inputs in Unit

36

Total Number of FVNR Starter Units

38

40

42

44

46

48

50

16

Integrated, Intelligent Motor Control Centers

Findings and Conclusions

The DeviceNet MCC cost is nearly identical to a motor control

center interwired with an I/O chassis. The choice, therefore
should be based on technology preference, not price.

As expected, the networked solution becomes more cost effective

as the amount of information returned per MCC unit (i.e. number
of inputs) increases.

Representative MCC Comparison

Additional Assumptions

All details listed under both the General Assumptions and the
Specific Case Assumptions apply.

MCC line-up includes eight NEMA Type 1 sections, with 800

ampere tin-plated copper main power bus, x 1 horizontal
ground bus, two power bus splice kits, two ground bus splice kits

FVNR starter unit quantities and sizes:

(10) Size 1
(9) Size 2
(7) Size 3
(4) Size 4
(1) Size 5

Lug provision included for main incoming lines, rated 800A

Starter units have three inputs (3I), one output (1O)

Total Inputs 93

Total Outputs 31

Larger, advanced function PLC requires two I/O chassis

Smaller, basic function PLC requires three I/O chassis

MCC with DeviceNet contains a unit with a DeviceNet to

ControlNet linking device and one 8 ampere DeviceNet power
supply unit

Integrated, Intelligent Motor Control Centers

17

Price Comparison
MCC interwired to MCC interwired to
a larger, advanced a smaller, basic
function PLC I/O
function PLC I/O
chassis
chassis
Sections

MCC with
DeviceNet

$13,722

$13,722

$13,722

672

672

672

65,983

65,983

65,983

Network communication interface module

in each starter unit

--

--

21,700

Power supply unit

--

--

2,400

PLC unit of linking

device unit

25,160

31,692

6,000

72

108

144

10,561

11,218

--

--

--

8,000

$116,170

$123,395

$118,621

Main lug provision

Starter Units

Doors
Class II wiring
Network Cabling
Total List Price

Prices derived using published list prices

Total Price Comparison for Representative MCCs

$130,000

Communication
interface module,
power supply unit,
network cabling
Class II wiring

$120,000
$110,000

Total Price

$100,000
$90,000

PLC or Linking
Device unit

$80,000
$70,000
$60,000

Sections, splice
kits, Main lug,
starter units, doors

$50,000
$40,000

MCC Interwired to MCC Interwired to DeviceNet MCC

Large I/O Chassis Small I/O Chassis

18

Integrated, Intelligent Motor Control Centers

Findings and Conclusions

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

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

Integrated, Intelligent Motor Control Centers

19

Appendix A
Case Study for Factory-interwired I/O Chassis
This white paper uses a factory-interwired MCC as the basis for
comparison to the DeviceNet MCC. Is this valid? Wouldnt a fieldinterwired MCC be a better basis? The factory-interwired pricing was
chosen because it is lower than the price for field interwiring. A
previous white paper documented the price comparisons. An excerpt
follows.
---------------------------Since 1980, more than 50,000 sections of MCCs have been interwired
to PLCs. The old concern about packaging logic devices in proximity
to high voltage has been sufficiently laid to rest by the overwhelming
success of these installations.
The question still surfaces as to who can interwire MCC units to the
PLC modules most cost-effectively: the MCC manufacturer or a local
contractor/panel shop. A major engineering construction firm wanted
to determine the answer, and conducted an independent study that
evaluated costs of interwiring PLC I/O chassis to motor control center
units. Their study compared costs for both an MCC manufacturer and
an electrical contractor to do the interwiring.
The comprehensive study was based on an actual user order that
needed an MCC and PLC chassis with 320 I/O points, to control a
manufacturing process with 25 motors. The study focused on three
methods for interwiring the motor control center and PLC chassis,
and reviewed costs to supply engineering, design, and construction
necessary to provide, install, and make the equipment operational.
The three methods were:
Case 1
Electrical contractor (panel shop) designs, assembles, and interwires
PLC chassis located in a separate programmable control cabinet to an
MCC.
Case 2
Electrical contractor (panel shop) interwires PLC chassis located in
an MCC.
Case 3
Motor control center manufacturer interwires PLC chassis located in
an MCC, making it a factory-interwired MCC.

20

Integrated, Intelligent Motor Control Centers

General Assumptions for All Cases

PLC I/O modules included for 160 inputs and 160 outputs.

All I/O are wired from PLC chassis to terminal blocks total of
640 wires, 1280 terminations.

25 output points are wired from the terminal blocks to motor

starter coils total of 50 wires, 100 terminations.

25 input points are wired from the terminal blocks to motor

starter auxiliary contacts total of 50 wires, 100 terminations.

Remaining 270 I/O (135 inputs, 135 outputs) are for field devices
and are located in the MCC for convenience.

Terminations are pressure-plate type and do not require wire lugs.

PLC cabinet or MCC sections sized for four I/O chassis (three are
purchased, one future space).

Hardwired emergency-stop relays and control relays (total of 24)

are wired to terminals, and are located in a dedicated MCC
compartment.

Internal MCC interlock wiring consists of 48 interlocks (two per

relay) total of 96 wires, 192 terminations.

Completion criteria for I/O wired to starters: Each PLC output

shall be energized, the unit control circuit tested, and feedback
from the starters auxiliary contact received at the input module.

Services and Materials Provided

Each case included estimates for engineering, drafting, materials, and
installation. Specific case descriptions are identified below.
The following services and materials were provided by others and are
common to all three cases. They are not included in the cost analyses:
Engineering

MCC single-line diagram and MCC arrangement

I/O assignments to load and inputs

Elementary wiring (schematic) diagrams for I/O and hardwired

emergency stop and control circuits

Material and Construction Costs

MCC incoming power

PLC programming software

Wiring from field devices and motors to MCC and PLC I/O
terminals

Integrated, Intelligent Motor Control Centers

Case 1
MCC and Separate
Programmable Control Cabinet
Wired by Electrical Contractor

21

Specific Case Assumptions

The PLC I/O chassis and I/O terminals are located in a separate,
freestanding NEMA 12 cabinet designed specifically for the
system (to include three I/O chassis with 320 digital I/O).

The PLC cabinet is located 10 feet (3 m) from the MCC (requires

20 feet [6.1 m] of conduit, 30 feet [9.1 m] of wire).

Interconnecting wiring between the PLC and MCC will be #14

AWG THHW / THWN copper wire routed in rigid galvanized
steel conduit.

Five 2-inch (50.8 mm) conduits with (128) #14 AWG wires each,
will be routed between the MCC and PLC cabinet.

Electrical contractor to wire I/O card wiring arms to the terminal

strips.

Engineering Deliverables
PLC cabinet layout drawing with bill of material.

Plan drawing showing location of MCC and PLC cabinet, and

conduit routing.

Interconnection wiring diagram showing wiring between PLC

and MCC.

Specify and purchase MCC.

Specify and purchase labor and materials for interwiring between

the PLC cabinet and MCC units.

22

Integrated, Intelligent Motor Control Centers

Case 2
Programmable Controller in
MCC Wired by Electrical
Contractor

Specific Case Assumptions

The assumptions are identical to Case 1, except:

The PLC I/O chassis and I/O terminals are located in dedicated
sections in the MCC.

I/O card wiring arms are wired to terminal strips by the MCC
vendor.

Engineering Deliverables

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

blocks, and relays.

Specify and purchase labor and materials for interwiring between

the PLC section and MCC units.

Integrated, Intelligent Motor Control Centers

Case 3
Programmable Controller in
MCC Wired and Tested by
MCC Manufacturer

23

Specific Case Assumptions

The assumptions are identical to Case 2, except:

MCC manufacturer makes all interconnections between the PLC

I/O chassis and MCC (facotry interwired MCC).

Engineering Deliverables

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

blocks, relays, and all interwiring (factory interwired MCC).

24

Integrated, Intelligent Motor Control Centers

Conclusion

This independent study shows that Case 3 has the lowest interwiring
cost- i.e. where the MCC manufacturer mounts and wires I/O in the
MCC (factory interwired motor control center).
The study data, combined with other factory interwired advantages like reduced start-up time, high quality wiring, and high quality
documentation - support the trend toward increased purchases of
factory interwired motor control centers.

Cost Breakdown - Case Study

Case 1

Case 2

Case 3

Labor Costs
Physical Design of PLC Cabinet and Control Room

$ 5250

--

--

2 AutoCAD Drawings-Panel Layout, COntrol Room

2500

--

--

Elec. Design of PLC Cabinet and Interconnection

5000

$ 5000

--

Interdiscipline Coordination, Quality, Management, Drawing Review

2500

2500

--

2 AutoCAD Drawings-Interconnection, Wiring

1680

1080

$ 840

Management, Scheduling, Meetings

1680

1680

1260

RFQ Creation/Analysis

2820

1440

1440

Assembly & Installation of P:LC Cabinet (incl. wiring to terminal blocks)

6284

--

--

Inspection(s) and Travel Expense

3920

1960

1960

Mechanical Installation of MCC

1500

2000

2000

Wiring Between MCC and PLC, Checkout

9570

4836

--

Relay Interlock Wiring

588

588

--

Field Start-Up Assistance

2400

2400

960

$ 45, 692

$ 23, 484

$ 8,460

Motor Control Center

44436

73992

81391

Enclosure, PLC Components, Terminal Blocks, Panduit, Etc.

24797

--

--

Relays for Safety Interlock

72

72

--

Wiring (and conduit) Between MCC and PLC

1706

276

--

$ 71, 011

$ 74, 340

$ 81, 391

$ 116,703

$ 97,824

$ 89,851

TOTAL LABOR COSTS

Material Costs

TOTAL MATERIAL COSTS

TOTAL COSTS

Rockwell Automation provided prices for:

Case 1 MCC and PLC component
Case 2 MCC with PLC (PLC price included in MCC price)
Case 3 MCC with PLC in MCC wired and tested

Integrated, Intelligent Motor Control Centers

25

Appendix B
Sample Data Point Calculations for Variable Size
Cost Comparison Graphs
The tables show data points used to generate the graphs found in the
Variable Size Cost Comparison section. All prices were derived
using published list prices.
Details about FVNR units, input and output modules, PLC units,
sections, splice kits, and doors are included in the General
Assumptions and Specific Case Assumptions on pages 10-12.
MCC with Larger, Advanced Function PLC

4 Inputs per Unit

3 Inputs per Unit

2 Inputs per Unit

# of
Units

# of
# of
Inputs Outputs

# of
# of
# of PLC
# of
Input Output
Chassis Sections
Modules Modules

PLC
Total

Unit
Total

Section
Total

Splice
Kit

Sub
Total

Door

Interwiring
Adder

Total

10

20

10

$11,157

$15,260

$3,352

$29,769

$2,977

$32,746

15

30

15

11,157

22,890

5,028

36

39,111

3,911

$43,022

20

40

20

14,762

30,520

6,704

157

72

52,215

5,222

$57,437

25

50

25

16,185

38,150

8,380

157

108

62,980

6,298

69,278

30

60

30

16,185

45,780

10,056

157

144

72,322

7,232

79,554

35

70

35

25,919

53,410

11,732

314

108

91,483

9,148

100,631

40

80

40

25,919

61,040

13,408

314

144

100,825

10,083

110,908

45

90

45

27,342

68,670

15,084

314

180

111,590

11,159

122,749

50

100

50

30,947

76,300

15,084

314

122,645

12,265

134,910

10

30

10

$11,157

$15,260

$3,352

$29,769

$2,977

$32,746

15

45

15

12,580

22,890

5,028

36

40,534

4,053

44,587

20

60

20

16,185

30,520

6,704

157

72

53,638

5,364

59,002

25

75

25

17,608

38,150

8,380

157

108

64,403

6,440

70,843

30

90

30

25,160

45,780

10,056

157

72

81,225

8,123

89,348

35

105

35

28,765

53,410

11,732

314

108

94,329

9,433 103,762

40

120

40

30,188

61,040

13,408

314

144

105,094

10,509

45

135

45

31,611

68,670

15,084

314

180

115,859

11,586 127,445

50

150

50

10

35,216

76,300

15,084

314

126,914

12,691 139,605

10

40

10

$12,580

$15,260

$3,352

$31,192

$3,119

$34,311

15

60

15

14,003

22,890

5,028

36

41,957

4,196

46,153

20

80

20

17,608

30,520

6,704

157

72

55,061

5,506

60,567

25

100

25

26,583

38,150

8,380

157

36

73,306

7,331

80,637

30

120

30

28,006

45,780

10,056

157

72

84,071

8,407

92,478

35

140

35

31,611

53,410

11,732

314

108

97,175

40

160

40

10

33,034

61,040

13,408

314

144

107,940

10,794

45

180

45

12

42,009

68,670

15,084

314

108

126,185

12,619 138,804

50

200

50

13

10

45,614

76,300

16,760

471

144

139,289

13,929 153,218

115,603

9,718 106,893
118,734

26

Integrated, Intelligent Motor Control Centers

MCC with Smaller, Basic Function PLC

4 Inputs per Unit

3 Inputs per Unit

2 Inputs per Unit

# of
Units

# of
# of
Inputs Outputs

# of
# of
# of PLC
# of
Input Output
Chassis Sections
Modules Modules

PLC
Total

Unit
Total

Section Splice
Total
Kit

Sub
Total

Door

Interwiring
Adder

Total

10

20

10

$9,991

$15,260

$3,352

36

$28,639

$2,864

$31,503

15

30

15

10,982

22,890

5,028

72

38,972

3,897

42,869

20

40

20

18,364

30,520

6,704

157

72

55,817

5,582

61,399

25

50

25

20,973

38,150

8,380

157

108

67,768

6,777

74,545

30

60

30

21,964

45,780

10,056

157

144

78,101

7,810

85,911

35

70

35

29,346

53,410

11,732

314

144

94,946

9,495

104,441

40

80

40

10

30,337

61,040

13,408

314

180

105,279

10,528

115,807

45

90

45

12

32,946

68,670

13,408

314

115,338

11,534

126,872

50

100

50

13

40,328

76,300

15,084

314

132,026

13,203

145,229

10

30

10

$10,982

$15,260

$3,352

36

$29,630

$2,963

$32,593

15

45

15

18,728

22,890

5,028

36

46,682

4,668

51,350

20

60

20

21,337

30,520

6,704

157

72

58,790

5,879

64,669

25

75

25

10

29,710

38,150

8,380

157

72

76,469

7,647

84,116

30

90

30

12

31,692

45,780

10,056

157

108

87,793

8,779

96,572

35

105

35

14

40,065

53,410

11,732

314

108

105,629

10,563

116,192

40

120

40

15

41,056

61,040

13,408

314

144

115,962

11,596

127,558

45

135

45

17

43,665

68,670

15,084

314

180

127,913

12,791

140,704

50

150

50

19

10

52,038

76,300

16,760

471

180

145,749

14,575

160,324

10

40

10

$17,737

$15,260

$3,352

$36,349

$3,635

$39,984

15

60

15

20,710

22,890

5,028

36

48,664

4,866

53,530

20

80

20

10

29,083

30,520

6,704

157

36

66,500

6,650

73,150

25

100

25

13

32,683

38,150

8,380

157

72

79,442

7,944

87,386

30

120

30

15

40,429

45,780

10,056

157

72

96,494

9,649

106,143

35

140

35

18

44,029

53,410

11,732

314

108

109,593

10,959

120,552

40

160

40

20

51,775

61,040

13,408

314

108

126,645

12,665

139,310

45

180

45

23

55,375

68,670

15,084

314

144

139,587

13,959

153,546

50

200

50

25

10

63,748

76,300

16,760

471

144

157,423

15,742

173,165

MCC with DeviceNet

# of PLC
Chassis

# of
Sections

10

$6,000

$22,260

$5,352

$33,612

15

6,000

33,390

8,028

36

47,454

20

6,000

44,520

10,704

157

72

61,453

25

6,000

55,650

13,380

157

108

75,295

30

6,000

66,780

16,056

157

144

89,137

35

6,000

77,910

18,732

314

180

103,136

40

6,000

89,040

18,732

314

114,086

45

6,000

100,170

21,408

314

36

127,928

50

6,000

111,300

24,084

314

72

141,770

Module with 4 inputs in Unit

# of
Units

PLC
Total

Unit
Total

Section
Total

Splice
Kit

Door

Total

Comparison of Total Costs

Total for MCC interwired to

Large I/O Chassis
# of
Units

% Difference for MCC with

DeviceNet / MCC
interwired to Large I/O
Chassis

Total for MCC interwired to

Small I/O Chassis

2 Inputs 3 Inputs 4 Inputs 2 Inputs 3 Inputs 4 Inputs

DeviceNet
Total

% Difference for MCC with

DeviceNet / MCC
interwired to Small I/O
Chassis

2 Inputs 3 Inputs 4 Inputs 2 Inputs 3 Inputs 4 Inputs

10

$32,746

$32,746

$34,311

$31,503

$32,593

$39,984

$33,612

2.6%

2.6%

-2.0%

6.7%

3.1%

-15.9%

15

43,022

44,587

46,153

42,869

51,350

53,530

47,454

10.3%

6.4%

2.8%

10.7%

-7.6%

-11.4%

20

57,437

59,002

60,567

61,399

64,669

73,150

61,453

7.0%

4.2%

1.5%

0.1%

-5.0%

-16.0%

25

69,278

70,843

80,637

74,545

84,116

87,386

75,295

8.7%

6.3%

-6.6%

1.0%

-10.5%

-13.8%

30

79,554

89,348

92,478

85,911

96,572

106,143

89,137

12.0%

-0.2%

-3.6%

3.8%

-7.7%

-16.0%

35

100,631

103,762

106,893

104,441

116,192

120,552

103,136

2.5%

-0.6%

-3.5%

-1.2%

-11.2%

-14.4%

40

110,908

115,603

118,734

115,807

127,558

139,310

114,086

2.9%

-1.3%

-3.9%

-1.5%

-10.6%

-18.1%

45

122,749

127,445

138,804

126,872

140,704

153,546

127,928

4.2%

0.4%

-7.8%

0.8%

-9.1%

-16.7%

50

134,910

139,605

153,218

145,229

160,324

173,165

141,770

5.1%

1.6%

-7.5%

-2.4%

-11.6%

-18.1%

Publication 2100-WP001A-EN-P - December 2000

2000 Rockwell International. All Rights Reserved. Printed in USA