Allen-Bradley Control System Packaging Reference Manual
Allen-Bradley Control System Packaging provides guidelines and recommendations for protecting electronic equipment in tire and rubber manufacturing environments. It focuses on mitigating the effects of corrosive gases and contaminants like carbon black, which can damage electronic components and circuits. The manual covers enclosure construction, cooling techniques, air purification strategies, and installation practices to create a suitable operating environment for the equipment.
advertisement
Design and Installation Guideline
Control System Packaging for Corrosion Mitigation
Prepared for:
The Tire and Rubber Industry
Control System Packaging for Corrosion Mitigation
Prepared for:
The Tire and Rubber Industry
Control System Packaging for Corrosion Mitigation
2 Rockwell Automation Publication TIRE-RM001C-EN-P - September 2018
Additional Resources
Resource Description
Preventive Maintenance of Industrial Control and Drive System
Equipment, publication DRIVES-TD001
General reference for conducting maintenance on any PowerFlex©
enclosure.
ISA 71.04-2013: "Environmental Conditions for Process Measurement
and Control Systems: Airborne Contaminants"
This standard covers airborne contaminants and biological influences
that affect industrial process measurement and control equipment,
electronic office equipment, and data center and network equipment.
Conformal Coating Protecting Your Automation Investment,
publication IA-PP001
Explains conformal coating to help protect components from moisture,
fungus, dust, corrosion, abrasion, and other environmental stresses.
PowerFlex520-Series Adjustable Frequency AC Drive, PowerFlex 523
Catalog Number 25A, Series B, PowerFlex 525 Catalog Number 25B,
publication 520-UM001
User manual for the PowerFlex 520 and PowerFlex 523.
You can view or download publications at http://www.rockwellautomation.com/global/literature-library/
overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
2 Rockwell Automation Publication TIRE-RM001C-EN-P - September 2018
Additional Resources
Resource Description
Preventive Maintenance of Industrial Control and Drive System
Equipment, publication DRIVES-TD001
General reference for conducting maintenance on any PowerFlex©
enclosure.
ISA 71.04-2013: "Environmental Conditions for Process Measurement
and Control Systems: Airborne Contaminants"
This standard covers airborne contaminants and biological influences
that affect industrial process measurement and control equipment,
electronic office equipment, and data center and network equipment.
Conformal Coating Protecting Your Automation Investment,
publication IA-PP001
Explains conformal coating to help protect components from moisture,
fungus, dust, corrosion, abrasion, and other environmental stresses.
PowerFlex520-Series Adjustable Frequency AC Drive, PowerFlex 523
Catalog Number 25A, Series B, PowerFlex 525 Catalog Number 25B,
publication 520-UM001
User manual for the PowerFlex 520 and PowerFlex 523.
You can view or download publications at http://www.rockwellautomation.com/global/literature-library/
overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Control System Packaging for Corrosion Mitigation
Rockwell Automation Publication TIRE-RM001C-EN-P – September 2018 3
Table of Contents
1.0 Introduction ......................................................................................................................................................... 4
1.1 Document Purpose and Audience ............................................................................................................................................................ 4
1.2 Document Application and Limitations .................................................................................................................................................... 4
1.3 Document Conventions ........................................................................................................................................................................... 5
2.0 Process Area Considerations .................................................................................................................................. 6
3.0 Enclosures ............................................................................................................................................................ 7
3.1 Enclosure Construction ............................................................................................................................................................................ 7
3.1.1 Acceptable Standards ........................................................................................................................................................................... 7
3.1.2 Construction Types ............................................................................................................................................................................... 8
3.1.3 Gaskets ........................................................................................................................................................................................... 8
3.2 Cooling .................................................................................................................................................................................................. 9
3.2.1 Conductive Heat Dissipation ................................................................................................................................................................. 9
3.2.2 Fans ......................................................................................................................................................................................... 10
3.2.3 Heat Exchangers ................................................................................................................................................................................. 10
3.2.4 Air Conditioners .................................................................................................................................................................................. 10
3.3 Air Purification ...................................................................................................................................................................................... 11
3.3.1 Coupon Testing................................................................................................................................................................................... 12
3.3.2 Purification Strategies ........................................................................................................................................................................ 12
4.0 Electrical Rooms ................................................................................................................................................. 13
4.1 Room Construction ................................................................................................................................................................................ 13
4.1.1 Walls and ceilings ............................................................................................................................................................................... 13
4.1.2 Doors and Seals .................................................................................................................................................................................. 13
4.2 Heating and Cooling .............................................................................................................................................................................. 13
4.2.1 Fans ......................................................................................................................................................................................... 14
4.2.2 Air Conditioners / Heating .................................................................................................................................................................. 14
4.3 Air Purification ...................................................................................................................................................................................... 14
5.0 Installation ........................................................................................................................................................ 14
5.1 Enclosures ............................................................................................................................................................................................. 15
5.1.1 Floor Mounted .................................................................................................................................................................................... 15
5.1.2 Mezzanine Mounted ........................................................................................................................................................................... 16
5.1.3 Electrical Room ................................................................................................................................................................................... 17
6.0 Recommendation Matrix by Process Area / Location ............................................................................................. 18
7.0 Recommended Inspection and Maintenance ........................................................................................................ 19
Appendix A Tire and Rubber Enclosure Audit ................................................................................................................... 20
Appendix B Enclosure Specifications and Requirements................................................................................................... 31
Rockwell Automation Publication TIRE-RM001C-EN-P – September 2018 3
Table of Contents
1.0 Introduction ......................................................................................................................................................... 4
1.1 Document Purpose and Audience ............................................................................................................................................................ 4
1.2 Document Application and Limitations .................................................................................................................................................... 4
1.3 Document Conventions ........................................................................................................................................................................... 5
2.0 Process Area Considerations .................................................................................................................................. 6
3.0 Enclosures ............................................................................................................................................................ 7
3.1 Enclosure Construction ............................................................................................................................................................................ 7
3.1.1 Acceptable Standards ........................................................................................................................................................................... 7
3.1.2 Construction Types ............................................................................................................................................................................... 8
3.1.3 Gaskets ........................................................................................................................................................................................... 8
3.2 Cooling .................................................................................................................................................................................................. 9
3.2.1 Conductive Heat Dissipation ................................................................................................................................................................. 9
3.2.2 Fans ......................................................................................................................................................................................... 10
3.2.3 Heat Exchangers ................................................................................................................................................................................. 10
3.2.4 Air Conditioners .................................................................................................................................................................................. 10
3.3 Air Purification ...................................................................................................................................................................................... 11
3.3.1 Coupon Testing................................................................................................................................................................................... 12
3.3.2 Purification Strategies ........................................................................................................................................................................ 12
4.0 Electrical Rooms ................................................................................................................................................. 13
4.1 Room Construction ................................................................................................................................................................................ 13
4.1.1 Walls and ceilings ............................................................................................................................................................................... 13
4.1.2 Doors and Seals .................................................................................................................................................................................. 13
4.2 Heating and Cooling .............................................................................................................................................................................. 13
4.2.1 Fans ......................................................................................................................................................................................... 14
4.2.2 Air Conditioners / Heating .................................................................................................................................................................. 14
4.3 Air Purification ...................................................................................................................................................................................... 14
5.0 Installation ........................................................................................................................................................ 14
5.1 Enclosures ............................................................................................................................................................................................. 15
5.1.1 Floor Mounted .................................................................................................................................................................................... 15
5.1.2 Mezzanine Mounted ........................................................................................................................................................................... 16
5.1.3 Electrical Room ................................................................................................................................................................................... 17
6.0 Recommendation Matrix by Process Area / Location ............................................................................................. 18
7.0 Recommended Inspection and Maintenance ........................................................................................................ 19
Appendix A Tire and Rubber Enclosure Audit ................................................................................................................... 20
Appendix B Enclosure Specifications and Requirements................................................................................................... 31
Control System Packaging for Corrosion Mitigation
4 Rockwell Automation Publication TIRE-RM001C-EN-P - September 2018
1.0 Introduction
1.1 Document Purpose and Audience
This document provides guidelines for the use of electronics or automation equipment in the tire and rubber
industry with respect to the protection of the product from corrosive gases and contaminants that are present in
the manufacturing environment. Rockwell Automation studies show that typical tire and rubber environments
are rated as G2 to GX per the ISA 71-04 standards for corrosion severity. Most products provided by Rockwell
Automation and competitors are specified to be installed in an environment free of corrosive gasses, vapors, and
dust. The focus of this document is to provide guidance on how and where to install the products to mitigate the
adverse conditions and to achieve a G1 or G2 corrosion severity in a particular environment per the ISA 71-04
standard.
The prime contaminants found in the tire and rubber environment are corrosive gases and carbon black.
Corrosive gases cause corrosion of the silver and copper on the circuit boards and components. Carbon black is a
contaminant that can build up on components and ultimately cause shorting on circuit boards or contacts. This
document focuses only on those contaminants.
First, the product must be installed following all of the manufacturer’s specifications and guidelines. Additionally,
product options such as conformal coating must be added (where available) to provide further protection from
the expected environment. Packaging the product in enclosures with temperature control, humidity control, and
filtering devices must also be employed. This document focuses on mitigation via packaging.
This document is intended for all users of electronics or automation equipment that are installed in the
manufacturing environments of the tire and rubber industry. This includes OEMs, system integrators, solution
providers, panel builders, and the end user.
See the Conformal Coating Protecting Your Automation Investment, publication IA-PP001, for information on
the Rockwell Automation conformal coated product offering.
1.2 Document Application and Limitations
Use this document as a guideline for design of the enclosures, implementation of mitigation devices, and
management of the contaminants that are present in the tire and rubber industry that effect electrical and
electronic devices. Following these guidelines decreases the effects of the contaminants on the electrical /
electronic components.
There is no single method to minimize the effects of the contaminants. In all cases, a combination of preventive
measures to reduce infiltration to the enclosures and remediation measures to remove contaminants present
should be implemented. There is not a complete solution or combination of solutions that will totally prevent the
effects of the contaminants and corrosive gases on the products beyond a totally sealed, air tight enclosure, which
is difficult to achieve. However, the more mitigation strategies the designer / user employs, the more likely that
the product will survive longer in the environment. Mitigation strategies will not stop contamination or
corrosion. The goal is to slow down the effects and extend the life of the product in the environment.
IMPORTANT Mitigation of the effects of contaminants and corrosive gases must be addressed in several ways.
4 Rockwell Automation Publication TIRE-RM001C-EN-P - September 2018
1.0 Introduction
1.1 Document Purpose and Audience
This document provides guidelines for the use of electronics or automation equipment in the tire and rubber
industry with respect to the protection of the product from corrosive gases and contaminants that are present in
the manufacturing environment. Rockwell Automation studies show that typical tire and rubber environments
are rated as G2 to GX per the ISA 71-04 standards for corrosion severity. Most products provided by Rockwell
Automation and competitors are specified to be installed in an environment free of corrosive gasses, vapors, and
dust. The focus of this document is to provide guidance on how and where to install the products to mitigate the
adverse conditions and to achieve a G1 or G2 corrosion severity in a particular environment per the ISA 71-04
standard.
The prime contaminants found in the tire and rubber environment are corrosive gases and carbon black.
Corrosive gases cause corrosion of the silver and copper on the circuit boards and components. Carbon black is a
contaminant that can build up on components and ultimately cause shorting on circuit boards or contacts. This
document focuses only on those contaminants.
First, the product must be installed following all of the manufacturer’s specifications and guidelines. Additionally,
product options such as conformal coating must be added (where available) to provide further protection from
the expected environment. Packaging the product in enclosures with temperature control, humidity control, and
filtering devices must also be employed. This document focuses on mitigation via packaging.
This document is intended for all users of electronics or automation equipment that are installed in the
manufacturing environments of the tire and rubber industry. This includes OEMs, system integrators, solution
providers, panel builders, and the end user.
See the Conformal Coating Protecting Your Automation Investment, publication IA-PP001, for information on
the Rockwell Automation conformal coated product offering.
1.2 Document Application and Limitations
Use this document as a guideline for design of the enclosures, implementation of mitigation devices, and
management of the contaminants that are present in the tire and rubber industry that effect electrical and
electronic devices. Following these guidelines decreases the effects of the contaminants on the electrical /
electronic components.
There is no single method to minimize the effects of the contaminants. In all cases, a combination of preventive
measures to reduce infiltration to the enclosures and remediation measures to remove contaminants present
should be implemented. There is not a complete solution or combination of solutions that will totally prevent the
effects of the contaminants and corrosive gases on the products beyond a totally sealed, air tight enclosure, which
is difficult to achieve. However, the more mitigation strategies the designer / user employs, the more likely that
the product will survive longer in the environment. Mitigation strategies will not stop contamination or
corrosion. The goal is to slow down the effects and extend the life of the product in the environment.
IMPORTANT Mitigation of the effects of contaminants and corrosive gases must be addressed in several ways.
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
advertisement
Key Features
- Corrosion mitigation strategies
- Enclosure construction guidance
- Cooling and temperature control
- Air purification techniques
- Installation recommendations
Related manuals
Frequently Answers and Questions
What are the primary contaminants found in tire and rubber manufacturing environments that affect electronic equipment?
The primary contaminants are corrosive gases and carbon black. Corrosive gases can lead to corrosion on circuit boards and components, while carbon black can build up and cause short circuits.
What are the acceptable standards for enclosures used in tire and rubber environments?
Rockwell Automation recommends using sealed IP54 enclosures. IP54 enclosures provide protection against ingress of solid foreign objects and water, minimizing contamination and corrosion.
What are some strategies for air purification in control system enclosures?
Strategies include positive pressure with filtered air, scrubbers for whole rooms, and the use of corrosive gas and solid absorption devices inside the enclosure.
advertisement