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JANUARY 2017
Vol. 64
Number 1
Features
32 How a PC-based control system is an

option for every application
COVER STORY: As industrial automation technologies accelerate,
PC-based control is an option for every application and for Industrial
Internet of Things (IIoT) and Industrie 4.0 initiatives.
IEEE 1722
PROFINET
IEC 61850
Future Industrial
Protocol
TM
ODVA EtherNet/IP
COVER STORY: Consider the features and typical applications for industrial controllers to understand what type of controller fits each application. See comparison tables for programmable logic controllers (PLCs),
programmable automation controllers (PACs), and industrial PCs (IPCs).
COVER: Controller images

by AutomationDirect (left), Emerson
(upper right), and Beckhoff Automation (lower right).
OPC-UA pub/sub
28 How to choose the best controller

for each application
IEEE/IETF defined, Avnu selected and certified common network services

Market-specific interoperability profiles for time synchronization, quality of service, network configuration, etc.
Certifiable open source software implementations with standard APIs, hardware reference designs, etc.
36
34 Choose the right control system

COVER STORY: Choosing between a programmable logic controller
(PLC) or a distributed control system (DCS) depends on the project and
plant. PLCs and a DCS differ in benefits, depending on the application.
36 What does time-sensitive networking and

real-time Ethernet data mean for industry?
Avnu Alliance members explain how real-time communications
enabled by Time Sensitive Networking (TSN) will strengthen the future
of industrial systems.
40
39 Five questions to ask when selecting a VFD

Those selecting a variable frequency drive (VFD) need to consider the
application, power source characteristics, and other safety and maintenance aspects to ensure smooth operation and minimal downtime.
40 Fundamentals of matrix
variable frequency drive technology
Providing cost, space, and energy efficiency for VFD applications.
44 System integrators help manufacturers

prepare and adopt IIoT
Get tips on the Industrial Internet of Things (IIoT), what it means for
manufacturing as a whole, and how system integrators can help in the
process from CFE Medias interviews of three representatives from
the 2017 System Integrators of the Year.
67 Digital Edition Exclusive

Incorporating cybersecurity awareness into OT
Robotics software for the next generation
JANUARY 2017
CONTROL ENGINEERING
44
CONTROL ENGINEERING (ISSN 0010-8049, Vol. 64, No. 1, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak
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CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license.
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JANUARY 2017
Vol. 64
Number 1
Inside Process
P1
Appears after page 44; If not, see the Digital Edition:

www.controleng.com/DigitalEdition
P7
P1 Six action items for an aging DCS/PLC

Plant and operations managers need to be aware that their distributed control systems (DCSs) and programmable logic controllers (PLCs) could be obsolete and they should take appropriate
steps to deal with the problem. Six immediate action items for
an aging system are highlighted.
P7 How to set up proper steam

condensate piping
Steam condensate systems must have proper piping to ensure
optimal performance.
Departments
8 Think Again
Hot topics in Control Engineering for 2016, 2017
12 Product Exclusive
Data acquisition and control system modules for industrial
applications
Products
68 Differential pressure
switches and indicators (right),
I/O for hazardous areas (below),
power supply modules, touchless angle sensors
14 Research
Original automation research; download more online
16 Control Engineering International

HMI evolution provides a gateway to productivity
18 Integrator Update
The eight key drivers to value a business
20 Technology Update
Five tips to modernize industrial network architectures
72 Back to Basics
69 Industrial PC, Panel

PC, Thermocouple measurement instrument, Pneumatic
valve manifold (right)
Principles for more effective automation
News
22
23
24
25
Continuous improvements; Interoperability specification for IIoT

CFE Media New Products for Engineers Database; Online motor testing
EtherCAT P specification document released, power and communication
Online headlines, events: 21st Annual ARC Industry Forum, Feb. 6-9; New Manufacturing USA Institute
www.controleng.com
70 Remote I/O with

EtherNet/IP, HMI PLCs for
small- and medium-sized
machines (left)
CONTROL ENGINEERING
JANUARY 2017
| 5
More resources posted daily at:
JANUARY
IIoT
www.controleng.com
New Products
Control Systems
Process Manufacturing Discrete Manufacturing
System Integration
Four aspects of good control

panel design
Theres a lot more to read online.
Go to www.controleng.com/news
to read Control Engineerings
exclusive Web content.
Networking & Security
Info Management
Education & Training
On-demand webcasts
See webcasts on demand
on a variety of topics at
www.controleng.com/webcasts.
Webcasts
Robots impact on global

economy projected to increase
Dec. 15: Industrial

Internet of Things Webcast Series 2016,
Part Four: Smart manufacturing, IIoT,
Industrie 4.0 case studies
How can system integrators help

with IIoT adoption?
Dec. 7: Cloud ERP Streamlines Operations in an Era of IIoT Data
The first three steps are always

the hardest
Nov. 11: IIoT and the Digital Oilfield:

Making Data Actionable
Monitoring a growing network by tracking data trends.
Oct. 20: Industrial Internet of Things

Webcast Series 2016, Part Three:
Security for IIoT.
NEW: With the launch of a quarterly supplement on Industrial Internet of Things

(IIoT) in 2017, weve expanded from one to four IIoT newsletters:
IoT: Machines & Equipment; IIoT: Operations & IT;
IIoT: Process Control & Automation; and the quarterly IIoT Report.
Subscribe at www.controleng.com/newsletters.
NEWSLETTER: INFORMATION CONTROL
Connecting information, engineering

and operational technologies
Keep up with the latest industry news
by subscribing to Control Engineerings
14 newsletters at
www.controleng.com/newsletters:
Finding IIoT benefits
IIoT analytic solution and platform
suppliers
Next steps in IT-based automation and
operations.
Point, click, watch

2017 System Integrator
of the Year winners
Bob Vavra (left) talks with Abhijit Jog
(left-center), Shawn Campion (right-center), and
Jack Woelber (right) about the present and future
for system integrators.
www.youtube.com/user/controlengineeringtv.
JANUARY 2017
CONTROL ENGINEERING
Control Engineering
Editorial Research Studies
Control Engineering
provides unique automation-industry research.
Research
2016 Industrial Internet of

Things, Industrie 4.0 Study
2016 System Integration Study: Five
findings on integrating systems
Control Engineering Salary and
Career Survey, 2016
2016 Cybersecurity Study:
Six key findings.
Read summaries and sign up to download the full report at
www.controleng.com/ce-research.
Digital Edition
The tablet and
digital editions of
this publication have
unique content for
digital subscribers. This month has
digital exclusives
on: Incorporating
cybersecurity
awareness into OT;
Robotics software for
the next generation.
www.controleng.com
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THINK AGAIN hot topics

1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
630-571-4070, Fax 630-214-4504
Content Specialists/Editorial
Hot topics: 2016, 2017

Control Engineering readers choose hot topics of 2016, and online
traffic points to key trends in Control Engineering in 2017.
New: See related articles of 2017 and top graphics of 2016.
The fundamentals of control engi-
neering, automation, and controls dominated

the hot topics in Control Engineering for 2016,
with articles on proportional-integral-derivative (PID) and loop tuning, control strategies,
and controller programming in the lead. See
leading graphics from the top 10 articles and
which 2017 articles relate to the top 10 hot
topics of 2016.
Because using the calendar year to tally
reader article traffic favors articles posted earlier in the year, also see this article online, with
links to hot topics posted later in 2016.
2016 articles: Hottest topics
Below are the hot control engineering topics of 2016, based on traffic at
www.controleng.com, January through
December.
1. Understanding PID control and loop
tuning fundamentals, July 26: These PID loop
tuning tips work.
2. Applying heat exchanger control strategies, Jan. 4: Inside Process: Integrating control schemes, such as feedback, cascade, and
feedforward techniques, can satisfy challenging control requirements.
4. Control Engineering Salary and Career

Survey, 2016, May 11: Control Engineering
research shows nearly a 5% increase in salaries
among respondents to an average of $94,747;
the economy is seen as the biggest threat.
3. IEC 61131-3: Whats the acceptance

rate of this control programming standard?
Feb. 16: Cover story: Although the IEC 611313 standard for control programming languages has been around for nearly 25 years,
limited awareness has kept it from becoming
a requirement in North America.
JANUARY 2017
CONTROL ENGINEERING
Contributing Content Specialists

Frank J. Bartos, P.E., braunbart@sbcglobal.net
Peter Welander, PWelander@CFEMedia.com
Vance VanDoren, Ph.D., P.E., controleng@msn.com
Suzanne Gill, Control Engineering Europe
suzanne.gill@imlgroup.co.uk
Ekaterina Kosareva, Control Engineering Russia
ekaterina.kosareva@fsmedia.ru
Wojciech Stasiak, Control Engineering Poland
wojciech.stasiak@trademedia.us
Luk Smelk, Control Engineering Czech Republic
lukas.smelik@trademedia.us
Aileen Jin, Control Engineering China
aileenjin@cechina.cn
Publication Services
Courtesy: Control Engineering 2016
Salary and Career Survey research report.
Jim Langhenry, Co-Founder/Publisher, CFE Media

630-571-4070, x2203; JLanghenry@CFEMedia.com
Steve Rourke, Co-Founder, CFE Media
630-571-4070, x2204, SRourke@CFEMedia.com
5. Ladder logic 105: PLC scanning, March

4: Understand how scanning works in a programmable logic controller (PLC), regardless
of the program being used.
Trudy Kelly, Executive Assistant,

630-571-4070, x2205, TKelly@CFEMedia.com
6. The velocity of PID, Sept. 6: Inside

Process: PID theory is best introduced as the
familiar second order differential equation via
the velocity form instead of the more traditional positional form.
Brian Gross, Marketing Consultant, Global SI Database

630-571-4070, x2217, BGross@CFEMedia.com
7. Process models facilitate feedback control: Feb.

1: Mathematical models of process behavior can be used to
improve the design
and performance of
feedback controllers.
Courtesy: Control Engineering
Courtesy: Shady Yehia, The Control Blog
Mark T. Hoske, Content Manager

847-830-3215, MHoske@CFEMedia.com
Jack Smith, Content Manager
630-907-1622, JSmith@CFEMedia.com
Kevin Parker, senior contributing editor, IIoT, O&GE
630-890-9682, KParker@CFEMedia.com
Emily Guenther, Associate Content Manager
630-571-4070 x2220, eguenther@cfemedia.com
Amanda Pelliccione, Director of Research
631-320-0655, APelliccione@CFEMedia.com
Joy Chang, Digital Project Manager
630-571-4070 x2225, JChang@CFEMedia.com
Chris Vavra, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
8. Neural networks in process control:

Neural network architecture, controls, Feb. 26:
Neural networks, used in process control for
years, have been applied in other fields with
success. (See art, top left, p. 10.)
9. Advanced process control and real-time
optimization, Jan. 10: Advanced process control
and real-time optimization can improve a plants
profitability and efficiency while accounting for
process constraints. (See art, lower left, p. 10.)
Elena Moeller-Younger, Marketing Manager

773-815-3795, EMYounger@CFEMedia.com
Kristen Nimmo, Marketing Manager
630-571-4070, x2215, KNimmo@CFEMedia.com
Michael Smith, Creative Director

630-779-8910, MSmith@CFEMedia.com
Paul Brouch, Director of Operations
630-571-4070, x2208, PBrouch@CFEMedia.com
Michael Rotz, Print Production Manager
717-766-0211 x4207, Fax: 717-506-7238
mike.rotz@frycomm.com
Maria Bartell, Account Director
Infogroup Targeting Solutions
847-378-2275, maria.bartell@infogroup.com
Rick Ellis, Audience Management Director
303-246-1250, REllis@CFEMedia.com
Letters to the editor: Please e-mail us your opinions to
MHoske@CFEMedia.com or fax us at 630-214-4504.
Letters should include name, company, and address,
and may be edited for space and clarity.
Information: For a Media Kit or Editorial Calendar,
email Trudy Kelly at TKelly@CFEMedia.com.
Reprints
For custom reprints or electronic usage, contact:
Brett Petillo, Wrights Media
281-419-5725, bpetillo@wrightsmedia.com
Publication Sales: See ad index

Editorial Advisory Board
www.controleng.com/EAB
David Bishop, president and a founder
Matrix Technologies, www.matrixti.com
Joe Martin, president and founder
Martin Control Systems, www.martincsi.com
Rick Pierro, president and co-founder
Superior Controls, www.superiorcontrols.com
Mark Voigtmann, partner, automation practice lead
Faegre Baker Daniels, www.FaegreBD.com\
www.controleng.com

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THINK AGAIN hot topics

10. Ladder logic 401: Data
acquisition and analysis, March
22: A programmable logic controller (PLC) is designed to provide
information on signal levels and
can capture and analyze data.
Hot topics in 2017
Courtesy: Process2Control, LLC
Courtesy: Intech Process Automation
MORE
ADVICE
GO ONLINE
With this article online at
www.controleng.com, link to the
top 10 articles for 2016 posted prior
to 2016, and links to other hot topic
articles.
When choosing topics for the

2017 editorial calendar, Control
Engineering uses input from online traffic, suggestions from subscribers, and from content managers from six Control Engineering
editions globally, more than 1,400
data points. Based on 2016s hot topics, the following 2017 topics seem
likely to be popular.
In this January issue, see topics on
controller selection strategies. In February, learn
about multivariable control and motor selection.
In March, see articles on edge computing, Big
Data, and industry standards. In April, read about
artificial intelligence for automation and predictive and adaptive motion control. In May see the
salary survey and career trends. In June, see sensor fundamentals. In July learn about controller programming efficiency. In August, examine
when to use closed-loop control. The September webcast will provide case study knowledge
from system integrators. In October, read about
the Engineers Choice Award Finalists 2018. In
November, learn about automation reliability. In
December read articles on simulation and the
building blocks of process control.
Think again about lending your expertise: See
all 2017 article topics, webcasts, and research study
descriptions at www.controleng.com/mediainfo.
Top graphics of 2016
From the top 10 articles, Mike Smith, Control

Engineering art director, selected leading graphics
on control strategies, education, neural networks,
process control math, and advanced process control. Smith made the selections based on graphic
interest for presentation. Review Control Engineering cover art at www.controleng.com/magazine.
CFE Medias Joy Chang did the annual tally; Chris
Vavra does the weekly and monthly analysis. ce
Mark T. Hoske, Content Manager

MHoske@CFEMedia.com
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Input #200 at www.controleng.com/information
GO ONLINE
www.controleng.com/products has additional products. Also see the product
section in the January 2017 print/digital edition of Control Engineering.
Interested in introducing a product to the world here? Contact Mark T. Hoske,
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Familiarity with
Industrie 4.0
Very familiar
Not very
familiar
13%
research
11%
34%
42%
2016 SYSTEM INTEGRATION STUDY:
Third-party system integrators
Thirty-four percent of respondents
to the Control Engineering 2016 System

Integration Study provide system integration services to third parties, as opposed
to performing only in-house system integration work or hiring system integrators. Below are five findings from this
study as they relate to third-party system
integrators:
1. System integration projects: An
average of 15 third-party system integration projects are performed per year; and
the average project size is $173,000.
2. Devices integrated: The top devices
these companies integrate for third parties are programmable logic controllers
or programmable automation controllers
(81%); human machine interface (HMI),
SCADA, manufacturing execution system,
batch, historian, design, or other software
(79%); and HMI hardware or equipment,
operator interface, control panels, alarms,
annunciators, data acquisition equipment,
or data recorders or plotters (76%).
3. Project effectiveness: Six in 10

third-party system integrators report
automation system integration to be
highly effective in their projects, compared to 35% moderately effective,
4% somewhat ineffective, and 1% not
effective.
4. Project success: More than half of
third-party system integrators consider
a project successful if the project stayed
on budget, was completed on time,
improved productivity, and produced a
quantifiable return on investment.
5. Most recent project: Looking at
their most recently completed system
integration project, 67% of respondents
indicated an on-time delivery, and 71%
were able to adhere to the budget
initially settled upon. ce
View more information at
www.controleng.com/2016SystemIntegration.
Amanda Pelliccione is the research director
at CFE Media, apelliccione@cfemedia.com.
Key challenges faced by third-party system integrators

53%
Client relations
Hiring engineering talent
for system integration
Hiring engineering talent
for industry expertise
Communication skills
47%
40%
Not very
familiar
Somewhat
familiar
Fifty-three percent of end users are

familiar with the Industrie 4.0 platform, up from 33% in 2015. Source:
Control Engineering 2016 Industrial Internet of Things & Industrie
4.0 Study
53%
of organizations follow
ANSI/ISA-99/IEC-62443 to protect
their control systems; another 34%
use ISO/IEC 27001/27002. Source:
Control Engineering 2016 Cybersecurity Study
4 in 10
facilities outsource
for cost management purposes,

to better focus on core competencies, and/or due to the lack of
skilled personnel on staff. Source:
Control Engineering 2016 Salary
and Career Study
37%
32%
Vendor relations
Regulations/codes
and standards
31%
31%
Sales skills
$218,151:
Average
system integration project size sur-
Competition
30%
vey respondents are involved with.
Continuing education
30%
Source: Control Engineering 2016
28%
Marketing
23%
Liability
18%
Cybersecurity
Other business skills
10%
The top challenges faced by these system integrators are client relations (53%), hiring
engineering talent for system integration (47%) as well as industry expertise (40%), and a
lack of communication (37%). Courtesy: Control Engineering
System Integration Study
More research
Control Engineering covers several research topics each year. All
reports are available at
www.controleng.com/ce-research.
www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION
14
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
CONTROL ENGINEERING international
HMI evolution provides

a gateway to productivity
Control Engineering Europe: Human-machine interfaces (HMIs) have evolved into sophisticated
computer systems capable of acting as automation gateways for controlling and monitoring an
industrial process, even remotely. Advanced HMI functions can save time in commissioning,
maintenance and production.
Conventionally, a human-machine inter-
HMIs act as the
primary gateway
to an automation
system and
directly reference
tags and alarms
in the controller,
alerting users
to a current or
potential issue.
MORE
ADVICE
KEY CONCEPTS
Human-machine interfaces serve
as a hub to multiple devices and
systems.
Advanced HMI features allow
secure remote connection.
HMIs help with alarms and troubleshooting.
GO ONLINE
www.controlengeurope.com
www.controleng.com/international
CONSIDER THIS
How could features available in new
HMIs increase your productivity?
16
JANUARY 2017
face (HMI) is viewed as a simple device which

allows user inputs to be translated into signals for
machines that, in turn, send information to the
user. Todays HMIs can be much more than this
and are no longer simply display devices with fancy
graphics.
Now, HMIs can display all the real-time information needed to control a system and also can
carry out monitoring operations for the machine.
An HMI accesses data from multiple sources and
reaches out to remote spaces, giving operators
instant access to operations from anywhere.
HMIs act as the primary gateway to an automation system and directly reference tags and alarms
in the controller, alerting users to a current or
potential issue.
The benefit of using an HMI as an automation
gateway is the reduced time taken in three critical areas, such as commissioning, production, and
maintenance. These, in turn, arise through three
key characteristics of the HMI: remote connectivity, easy interaction, and advanced troubleshooting.
Advanced remote connectivity
By being able to interface with standard control

networks (Ethernet, RS-232, and RS-422/485) and
providing options for other networks (such as CCLink, CC-Link IE, and Melsecnet/H), it is possible
to monitor devices remotely, yielding reductions in
maintenance times and minimizing downtime.
Fast, convenient integration into control and
automation networks enables the HMI to control
and monitor other devices, such as programmable
logic controllers (PLCs), servo drives, frequency
inverters and robots. An HMI can interface directly
to databases in a manufacturing execution system
(MES), effectively acting as a communication hub
within a factory-wide automation system.
Advanced functions may enable an HMI to be
operated remotely on a client-server architecture
with a one-to-one connection. The exclusive control of operating authority prevents operational
errors that may be caused by simultaneous operation; in addition, setting passwords prevents illegal
viewing or operation.
CONTROL ENGINEERING
Mobile HMI software can provide a flexible

option for remote control and viewing of HMIs.
It allows up to five devices to be connected to an
HMI, so users can connect via an Apple iPad, a
Microsoft Windows phone, and a laptop PC at the
same time, for example. It allows the user to look at
different screens than the ones being displayed on
the HMI. In addition, it does not lock out the operator from using the HMI during remote viewing.
Easy HMI interactions
During setup and maintenance, HMIs can

monitor and modify sequence programs and
parameters, removing the need for an external programming device or changing cable connections.
Such a feature enables users to connect a PC to the
HMI and link through it transparently to connected
automation equipment. Using the HMI as a gateway
simplifies setup, programming, monitoring, modification and testing of components which might be
mounted deep within a panel or machine.
Advanced troubleshooting features, which are
designed to identify and help quickly eliminate
faults. Debugging functions within the HMI avoid
the need to use an external PC to commission and
fault find. Even whole user manuals now can be
stored on an HMI for direct access in the field. This
is more convenient and can help increase plant uptime by allowing for more efficient on-site support.
Data logging enables users to uniformly manage
data from multiple factory automation devices connected to an HMI for later analysis. With backup
and restore functions, the parameters and programs
of connected equipment, such as PLCs and inverters, can be stored on the HMI. Then, if a problem
arises on a piece of equipment or a new component
needs to be installed, the program or parameters
can be quickly restored without the need to connect
a PC, minimizing downtime. ce
Andr Hartkopf is product manager Visualization
at Mitsubishi Electric Europe B.V. This appeared
on the Control Engineering Europe site on Dec. 6,
2016, and was edited for use here by Mark T. Hoske,
content manager, CFE Media, Control Engineering,
mhoske@cfemedia.com.
www.controleng.com
CFE Medias
New Products for

Engineers Database
Looking for new products?
Look no further!
The New Products for Engineers Database is a platform that
provides an opportunity for engineering and
technical professionals to access the latest NEW
product information for the manufacturing,
commercial construction, and
manufacturing control industries.
Start searching now!

www.controleng.com/NP4E
8M
INTEGRATOR UPDATE business value
Eight key drivers to

value a business
Part 6 examines ways to drive value to a business: Create a business strategy by learning the eight
key ways to drive value in a system integration, automation, or engineering consulting business.
The eight
key drivers
of value
Eight key drivers of value
help guide
business
strategy and
day-to-day
decisions.
MORE
ADVICE
KEY CONCEPTS
The eight key ways to drive business value.
Questions to ask when considering
each key business driver.
The framework to use to drive more
value to a business.
GO ONLINE
For more about business valuations
and links to parts 1 to 5, read this
article online. In the digital edition,
click on the headline or search the
headline for www.controleng.com.
CONSIDER THIS
What types of questions should be
asked for businesses within a certain
industry?
18
Many business owners of system integration, automation, or engineering consulting firms

find themselves beyond busy every day, yet they
may not see the business results they are looking
for. Its especially frustrating when these results are
inconsistent with industry trends.
Successful business owners generally rely on a
variety of managerial frameworks to help make sure
they are on track with strategic plans and implementation. The following framework can be used
to set strategic direction to drive value in a business.
JANUARY 2017
The following are eight key drivers of value.
1. Financial performance: The history of

producing revenue and profit combined with the
professionalism of your record keeping.
2. Growth potential: The likelihood to grow the
business in the future and at what rate.
3. Switzerland structure: The businesss dependency on any one employee, customer, or supplier.
4. Valuation teeter totter: Whether the business is a cash suck or a cash spigot.
5. Recurring revenue: The proportion and
quality of automatic, annuity-based revenue collected each month.
6. Monopoly control: How well is the business differentiated from the other competitors in
the industry.
7. Customer satisfaction: The likelihood
that customers will re-purchase and also provide
referrals.
8. Hub and spoke: How would the business
perform if a key employee were unexpectedly
unable to work for a period of 3 months.
The eight key drivers of value help guide business strategy and day-to-day decisions. Start by
listing each of these drivers, then add bullet points
for the types of decisions you and your team make
CONTROL ENGINEERING
that fall within each category. Dont worry at this

point how much each driver may impact value,
just try to include at least three topics within each
that may contribute, either positively or negatively, to value. Next, discuss it with the team and
determine what changes need to be made and
what impact these changes may have versus the
resources it would take to implement.
Once the list is made, you can even turn this
into a dashboard and have the management team
report back on a monthly basis to track progress
and use it to set clear priorities.
This framework begins to illustrate how much
more goes into the value of a company than simply the financials and should spark some ideas on
what questions need to be asked to help focus on
the value drivers of the business. Identifying and
discussing these topics are critical to driving value
in the business.
What areas of the business could benefit from
a pricing review? What process adjustments could
help the business operate more smoothly? What
services are offered, or could be offered, that
would create a recurring revenue stream through
a subscription-type model or at least create more
repeat customers?
Sometimes the best ways to get fresh ideas
for a business is to look at entirely different
industries. For the next month, as products and
services are purchased either personally or professionally, pay close attention to the details of the
experience pre- and post-purchase. Make notes of
anything that stands out, whether positive or negative, then take a few minutes each week to look
at the list and see what parallels there are to your
business.
Whether you are considering selling your business in the near future or not for years to come,
its never too soon to start thinking about ways to
drive value for the best possible outcome when
that day comes. After all, your business is your
investment as well as your job. Drive value. ce
Catherine J. Durham is accredited senior analyst,
principal, and president, Capital Valuation Group.
Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media,
eguenther@cfemedia.com.
www.controleng.com
CFE Medias
Global System Integrator Database

CFE Medias Global System Integrator Database is an interactive community
of global end-users and system integrators hosted by Control Engineering, Plant
Engineering, and our global partners in Asia and Europe.
The newest version of the online database is even easier to use.
Features and updates:
Relevancy score indicates how closely
New feature allows an end-user to
Users can now preview the most
The most relevant data about an
an integrators qualifications match a

users search criteria
pertinent data of a System Integrator

before clicking to view the full
corporate profile
request a quote for a project directly

from the database site
integrators engineering services appear

on one page on their corporate profile
other details are organized by tabs.
As a Systems Integrator there are quite a few options available

for online advertising. They vary in functionality and design,
but the Global System Integrator Database has been our go to.
It is easy to use, professionally designed, and has given us a great
deal of exposure to clients we wouldnt normally be able to reach.
We have had more clients contact us with this solution than any
other System Integrator database combined. We not only going
to renew our profile this year, we plan on upgrading.
William Aja, Panacea Technologies
Find and connect with the most suitable service

provider for your unique application.
www.controleng.com/global-si-database
5A
TECHNOLOGY UPDATE modern networks
Five tips to modernize

industrial network architectures
Optimize an industrial network design and stay ahead of potential future challenges by deploying
a modern network architecture and following certain design tips.
A modern industrial Internet protocol (IP)

network infrastructure has been increasingly
essential for most manufacturers and industrial
companies.
By using the latest networking technologies,
breaking down data silos, and harnessing the power
of greater connectivity and information sharing,
the potential of smart manufacturing becomes a
reality. This can help make real-time operations
decisions and improve productivity in new ways.
Key design and deployment
considerations
For most organizations, network modernization

involves bringing together information-technology
(IT) and operations-technology (OT) systems into a
converged network architecture.
No modernization project to design and deploy
an industrial network will be the same. Some general considerations should be kept in mind to help
optimize a network design and address risks.
1. Collaborate upfront
MORE
ADVICE
KEY CONCEPTS
Tips for deploying an optimized
modern network architecture.
Key considerations for designing a
modern network architecture.
Things to consider while
implementing a modern network
architecture.
GO ONLINE
For related links about networking
architecture, read this article online.
In the digital edition, click on the
headline or search the headline for
www.controleng.com.
Read more online about design
and employment considerations
and benefits for modern network
architectures.
CONSIDER THIS
What are the challenges of
implementing/maintaining a modern
network architecture?
20
JANUARY 2017
Modernizing a network infrastructure shouldnt

be a go-it-alone venture for IT or OT. Rather, it
needs to be a collaborative effort that involves functional teams from across organizations. Early dialogue can help minimize any cultural differences by
getting buy-in from all stakeholders. Upfront collaboration is crucial to identifying potential risks.
2. Use design and deployment

resources
Industry guidance and resources are invaluable

during a network modernization project.
Rockwell Automation and Cisco jointly developed the Converged Plantwide Ethernet (CPwE)
guide to provide design guidance, tested and validated reference architectures for deploying futureready network architectures.
3. Choose the right protocol
One of the most critical decisions that will be

made while designing the network infrastructure is
selecting the right industrial Ethernet protocol.
Today, manufacturing and industrial companies are seeking to capitalize on the proliferation of
CONTROL ENGINEERING
connected smart devices that make up the Industrial Internet of Things (IIoT). IIoT devices use the
IP, which provides the common language for different devices to coexist and interoperate on the same
network. Adoption of IIoT technologies will be a
defining characteristic of the industrial sector for
the next several years.
4. Use a holistic security approach
More connection points in a modern industrial

IP network architecture also brings greater security risks.
No single security product, technology, or
methodology can be expected to contain todays
massive threat landscape on its own. A securitythrough-obscurity approach is no longer sufficient.
Instead, a holistic security approach is needed to
help protect people, operations, intellectual property, and other assets.
An industrial security program should start
with a security assessment to identify risk areas
and potential threats. From there, plan to deploy a
defense-in-depth security approach that establishes
multiple layers of defense.
5. Plan for the future
The infrastructure lifecycle in the industrial

automation space is typically between 15 and 20
years. But down the road, imagine what your operations will look like or how you will be using information given all the innovation thats occurring
today? This is why its important that the industrial
network infrastructure addresses the facilitys current needs while also anticipating those of tomorrow. Workforce changes also should be considered.
The key to making smart manufacturing possible is designing a modern network architecture
one that not only meets the needs of the facilitys immediate needs, but also addresses potential growth. ce
Gregory Wilcox is the global technology and business development manager at Rockwell Automation.
Edited by Emily Guenther, associate content
manager, Control Engineering, CFE Media,
www.controleng.com
How to
modernize
your factory
on your terms!
Modernize your
manufacturing without
sacrificing productivity
Siemens can help you implement more modern, earlier-life

solutions according to your needs with a stepped or phased
approach so you can retain your current level of productivity.
With no-charge code-conversion services, your existing assets
will be protected as you upgrade to the Totally Integrated
Automation (TIA) Portal, which retains your current structures
and naming conventions.
usa.siemens.com/modernize-ce
2016 Siemens Industry, Inc.
Choose a retrofit / replacement path that matches your

production and budget
INDUSTRY NEWS and events
Begin continuous improvements

The biggest challenge in most organizations is maintaining a competitive edge
while making relevant improvements consistently for customers. Meeting these challenges requires change.
Everyone from the boardroom to the
production floor has a difficult time overcoming the fear of change. As a result,
efforts to continuously improve are stalled
from the beginning. Fear of failure also factors in because no one wants to make a
mistake or look bad. Innovation cant come
from a controlled situation. Delegating or
forcing the issue cannot create it. It comes
from spontaneity and chaos.
If continuous improvement or innovation is to succeed, employees must feel
that their suggestions are genuinely wanted
and encouraged. They must willingly take
ownership in the organization. Continuous improvement is everyones responsibility. Every employee can launch initiatives
to create an environment where the focus
on continuous improvement happens daily.
Consider these four tips:

1. Study game films approach. Every
important project is reflected upon regardless of the outcome. Based on the outcome,
what needs to be known? If a similar project is acquired, what should be the first
course of action? What should be stopped
or done more often? This simple process
insures something is learned from every
event. Most employees know what they
must do, when to do it, and how to do it.
Many do not know why they do it, who
they do it for, and where it fits in to the
total picture. Being armed with the why,
who, and where helps them identify and
suggest ways to improve what they do.
2. Solicit feedback on how work is
produced in regularly conducted meetings. The first question should be based
on the one thing that can be done today
to produce a better result tomorrow. The
same approach should be taken with better
customers. They can offer a lot when asked

and shown that feedback is important.
3. Dont let the potential for mistakes
or failure deter innovation. There will
always be rough times. The team should be
shown that everyones actions and mistakes
are part of business and offer an excellent
opportunity to learn how to improve.
4. Evaluate important strategic issues
in a weekly meeting. Even one or two of
these meetings would be beneficial each
month to identify and act on tasks that
support continuous improvement. Whats
one thing that could be done better? is a
question that should be asked at every staff
meeting. This encourages feedback and
empowers team members to take ownership in the continuous improvement effort.
Chris Ruisi is a leadership and motivational business speaker and an author for
AME, a CFE Media content partner.
Interoperability specification for IIoT launched
share information. This can effectively

he CC-Link Partner Association (CLPA)
achieve communication between differand Profibus & Profinet International
ing parts of a line on separate networks,
(PI) announced an interoperability
hugely increasing transparency and
specification between CC-Link IE and Profiintegration.
net. CC-Link IE is used in the Asian Market,
Both the CLPA and PI expect to see the
while Profinet is most prevalent in Europe,
first supported products coming to market
therefore the new specification will greatly
sometime in 2017, with some partners
simplify integration and increase freedom
already showing enthusiasm for the new
of choice for end users who source produccollaboration. This means that the original
tion machinery globally. After less than a
concerns of end users, which sparked the
year of work, the specification will be made
collaboration, will have been addressed in
available to members of both organizations,
less than two years, displaying both orgawhich will allow them to develop hardware
nizations commitment to addressing users
products to support the new specification.
Fumihiko Kimura (left), CLPA Chairman,
needs, the groups noted.
Promoting transparency and ease of
and Karsten Schneider, PI Chairman.
Karsten Schneider, chairman of PI, said,
integration is one of the primary conCourtesy: CLPA, PI
We are delighted to offer our users direct
cerns for achieving concepts such as the
solutions to their requirements, in conjunction with the CLPA, whose
Industrial Internet of Things (IIoT). Many end users will source
aims are synchronous with our own.
production machinery from across the world, which may result in
The CLPA is pleased to be working with PI and our partners to
machines in the same plant that communicate via differing prooffer support to end users who need this interoperability. The cooptocols. This can lead to increased engineering work to achieve
eration between CLPA and PI will directly help to make concepts
integration as users are combining heterogeneous architectures
such as Industrie 4.0 a reality, said Naomi Nakamura, global director
that may not necessarily communicate as standard. End users of
of the CLPA. Increased openness and accessibility is what our end
both networks flagged these challenges to the CLPA and PI, which
users demanded, so we are pleased to be able to support them fully
cooperated to find solutions.
with this new specification.
The specification centers on the functionality of a coupler
Edited from a CLPA press release by CFE Media. See more Control
device, which allows transparent communication between CCEngineering IIoT and Industrie 4.0 stories at www.controleng.com.
Link IE and Profinet. As a result, both networks can seamlessly
22
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
CFE Media launches New Products for Engineers Database

CFE Media Technology, a division of CFE
Media, the publisher of Control Engineering,
has released a New Products for Engineers
tool; a unique software as a service (SaaS)
platform that provides valuable services
to engineering users who are interested in
discovering new products, and vendors who
would like to promote new products to engineers. User benefits include the following.
Engineering and technical professionals
can quickly access the latest new product
information for the manufacturing, commercial construction, automation and control
industries.
Engineers can rate and provide feedback
on new products.
Engineers can set up automatic notifications allowing aggregation and delivery of
select, new product information on a predetermined, scheduled basis.
New product vendors can easily upload,
edit and manage their new product information within the platform.
Vendors have the ability to enhance their
product profiles with media files, spec
sheets, case studies, and videos to give end
users valuable product information.
and information needs, said Steve Rourke,

CEO CFE Media LLC. Our latest database
platform allows them to quickly find and
peruse new products and set up new product
notification messages that will keep them
informed of any new product or desired company related updates.
The New Products for Engineers Database has a community of manufacturers that
provide new and updated products, which
are searchable within the database. The
database is hosted by Control Engineering,
Consulting-Specifying Engineer, Oil & Gas
Engineering, and Plant Engineering.
Rugged Precision
The MAQ20 Industrial
Data Acquisition & Control System
Our global engineering audience takes

pride in knowing what new products are
immediately available to help them better
address their production performance, safety,
Why online motor testing

is a great PdM tool
When properly installed in the correct application, electrical motors fill a
particular need. If well cared for, they
can operate safely and economically for
years. Among options for industrial motor
testing is online testing. Periodic off-line
motor testing may be needed, but online or
dynamic testing typically yields the most
benefit with a preventive maintenance
program. Online testing is done while
the motor is operating within its normal
environment at standard loads. It provides
information including the existence of
undesirable conditions (imbalance, high or
low voltage levels, and distortion).
David Manney, marketing administrator, L&S Electric. L&S Electric is a CFE
Media content partner.
CONTROL ENGINEERING
JANUARY 2017
| 23
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INDUSTRY NEWS
EtherCAT specification
document released
he EtherCAT Technology Group (ETG)

has published a first draft of the official EtherCAT P technology specification
with the extension of all corresponding
documents on its website. Additionally, an
application note has been finalized as a
guideline to implement EtherCAT P slaves.
EtherCAT P is an industrial Ethernet
technology that combines EtherCAT communication and power lines into one standard 4-wire Ethernet cable. Soon after the
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and power lines into

one standard 4-wire
Ethernet cable.
introduction of EtherCAT P, this technology

extension to EtherCAT was included in the
work of the EtherCAT Technology Group.
Ever since, the ETG has been developing
an official specification document and the
first draft has now been published. The
document, ETG.1030 EtherCAT P Specification defines the basics of EtherCAT P
as an extension of the physical layer of the
EtherCAT technology. As such, all other
EtherCAT standard documents in which
EtherCAT P will be integrated have also
been extended.
An EtherCAT P application note, which
provides a guideline for designing EtherCAT P slaves, has also been published.
This application note includes the according extension of the EtherCAT implementation including the associated connectors, electrical specifications as well as
recommendations for EMC-compliant
design. The application note highlights the
different design requirements, especially
with regard to the usage and connection
of supply voltages, and describes calculations on the basis of existing currents and
voltages in the network.
Edited from an EtherCAT Technology
Group press release by CFE Media.
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20.12.16 08:49
JANUARY 2017
CONTROL ENGINEERING
Digital edition? Click on headlines for more details.

See news daily at www.controleng.com/news
Headlines online
Industry events
At www.controleng.com, on the right side,
click on the events box and scroll by month
to see related industry events including:
21st Annual Arc Industry Forum,
Orlando, Feb. 6-9
www.arcweb.com/events/
arc-industry-forum-orlando
company and two staffing agencies for their

roles in the death of a 20-year-old woman.
Transformers are key for electrical safety
Proper installation and maintenance of an
electrical systems components help keep
the working environment safe while extending the life of the equipment.
Tips for training

a multigenerational workforce
Managing a generationally-diverse maintenance staff can be challenging at times,
but the wide range of skills and experiences
gained from a multigenerational workforce
can drive high productivity once reigned in.
Automate 2017, Chicago, April 3-6

www.automateshow.com
Wind Dallas 2017, Dallas, April 10-12
www.windenergyupdate.com/
operations-maintenance-usa
Hannover Messe, Hannover, Germany,
April 24-28, www.hannovermesse.de/home.
Top 5 Control Engineering articles

Dec. 5-11: The most visited articles included
DCS/PLC action items, robotic advances,
Engineers Choice finalists, PID and digital
control efficiencies, and configuration implementation considerations.
Chemical engineering organization
to lead manufacturing institute
The U.S. Department of Energys Office of
Energy Efficiency and Renewable Energy
announced the American Institute of Chemical Engineers (AICE) will lead the tenth
Manufacturing USA Institute.
Motion control shipments up in 2016
The MCMA reported that global shipments
for motion control products increased by
five percent to $2.4 billion in the first nine
months of 2016, which makes up for the
contraction the industry had in 2015.
Test beds for smart manufacturing:
Affordable, accessible, innovative
The Smart Manufacturing Leadership
Coalition (SMLC) is working on test-bed
demonstrations, which can help analyze
optimization, energy efficiency, safe and
sustainable production, and improved supply chain connectivity. The Coalitions efforts
include toolkits for smart manufacturing
deployment, and open, advanced platforms,
analytics, controls, and sensors.
PMI ends 2016 on a note of optimism
Manufacturing index for December jumps to
highest level since March 2015 as production, new orders are sharply higher.
OSHA levies $2.5 million fine
OSHA levied $2.5 million in fines against
an Alabama-based metal parts stamping
CORRECTION
The pull quote on page 39 in the December issue
for Control Engineering should have stated, Wellcontrolled reactors typically see an increased yield
CONTROL ENGINEERING
JANUARY 2017
| 25
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5 Ways Modern Integrated Automation

Makes Plants Safer
John DSilva | Safety Product Manager, Siemens Industry Inc.
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Within the past decade, advancements in automation
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Once perceived as a burdensome cost of doing business,
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The highest-performing automation systems integrate

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Many controllers on the market lack safety-integration
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Learn 5 ways that todays most advanced integrated

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Wireless Gas Monitoring

The emerging solution for improving plant safety
Wil Chin and Joe Manicni | United Electric Controls
Greg LaFramboise | Retired Wireless Technology Lead, Chevron
Industrial processes such as oil and gas production facilities,

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toxic and combustible gases, which can create serious hazards
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To minimize risk to personnel and plant safety, plants often deploy early warning devices such as
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This concern is driving a trend
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COVER STORY selecting a controller
How to choose the best

controller for each application
Consider the features and typical applications for industrial controllers to understand what type of
controller fits each application. Do you need a programmable logic controller (PLC), programmable
automation controller (PAC), or industrial PC (IPC)? See comparison tables for PLCs, PACs, and IPCs.
MORE
ADVICE
KEY CONCEPTS
How to choose the best controller
for an application.
The types of controllers and their
features.
Typical applications for industrial
controllers.
GO ONLINE
For related links about controllers, read this article online. In the
digital edition, click on the headline
or search the headline for www.
controleng.com.
For more on controllers, see pulldown controller pages under Control
Systems and Info Management at
www.controleng.com.
CONSIDER THIS
What are the costs associated with
not specifying new control systems
and taking advantage of additional
features, functions, and flexibility?
utomation controller applications

are widespreadas are the overlapping capabilities of programmable logic controllers (PLCs),
programmable automation controllers (PACs), and industrial PCs (IPCs). Most
of these controllers will work in discrete, process, and hybrid control applications to varying degrees, but what criteria should be used to
choose the right controller for an application?
(See Figure 1.)
To help understand what controller fits each
application best, there are merging features of
automation controllers to identify. Examining
typical applications can highlight similarities and
differences among these controllers.
Understanding the types of

control systems
With the many controller choices, a basic

understanding of the different types of controllers is important. Even within each controller system type, such as the PLC, there can be
several families of controllers from low-end to
high-end, with a wide range of functionality

among families. The following are among controller types:
The PLCthe original relay replaceris
what started it all nearly 50 years ago. Its suitable for controlling a wide variety of applications. Although available in many fixed input/
output (I/O) formats with minimal expansion,
(often called brick PLCs) the most common
form factor is a rugged, modular, rack-based
design that allows flexible configuration of the
I/O based on the system requirements. The central processing unit (CPU) of a PLC is typically a
purpose-designed controller with limited serial
and Ethernet communications capabilities. The
PLC commonly uses ladder logic programming,
although other options are often available, and
is a very competitively priced machine control
option.
The PAC is the next-generation PLC. While
these controllers are similar in form factor and
design to the PLC, the PACs newer technologies, borrowed from innovations in consumer
PCs and mobile device design innovations, have
advanced their capabilities. PACs typically have
expanded communications and data-logging
capabilities compared to PLCs.
PACs also have a variety of programming
options, typically centered around the International Electrical Commission (IEC) 61131-3
programming standard, which extends control
capability into high-end applications. But even
with high-end programming available, the PACs
roots are still in ladder logic.
The IPC is a PC built to operate reliably in
an industrial environment. But with newer and
smaller component designs and more compact
operating systems, the IPC no longer looks like
a desktop PC or even a panel-mount PC, two of
the most common form factors.
Figure 1: A wide variety of controllers are available today, allowing users to

pick the exact type and model of controller for their specific application. All
graphics courtesy: AutomationDirect
28
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
The IPC is now being designed for DIN-rail

or rack mounting, which expands the application
space. Because an IPC is a PC at heart, its theoretical maximum processing power and communications and data storage capabilities are
unmatched by PLCs or PACs.
Some early versions of the IPC received some
strong criticism because they were not as rugged
as they should have been and because their operating systems were very unstable, but todays versions have improved.
Controller feature comparison
Many considerations go into selecting a control solution, and it begins with the application.
Its important to fully understand application
needs as well as the desired results from the control system to adequately specify the required
features.
Controller features can be wide-ranging,
spanning from the very basic (like the total I/O
required) to the more detailed specifications
(like data handling capabilities). Consider the
features listed in Table 1 when selecting a controller for each application.
Keep in mind that these rankings are subjective, and results may vary.
Serial communications are well-established in
industrial applications and have been, and will
be, around for a while. Serial communications
have the ability to effectively communicate with
many standard devices via RS-232 and RS-485
digital data links, but Ethernet communication
has taken a bite out of serial communications
and will continue to do so in Industrial Internet
of Things (IIoT) and other web-based applications. In addition to being a good fit in the IIoT,
Ethernet can communicate to standard devices
with a typical 10/100 Mbps connection.
Standard protocol communications include
the ability to talk to typical industrial devices
using popular protocols such as Modbus remote
terminal unit (RTU), Modbus transmission control protocol (TCP), EtherNet/IP, Profinet, etc.
Custom protocol communications allow controllers to talk to nonstandard industrial devices
using custom-written protocols that execute in
the controller.
A suitable amount of memory needs to be
available for the controller program and I/O
and for storing application data files, tag names,
descriptions, etc. Adequate CPU capabilities
ensure the controller has the computing power
necessary to accommodate the application at
hand including fast scan times, logic, data and
communication handling, and other functions.
www.controleng.com
Simple programming provides a straightforward environment for control of basic

machines and systems, typically using one language such
as a ladder diagram. Enhanced
programming provides a more
flexible, but more complex,
user interface with a variety of
programming options including a ladder diagram, structured text, functional diagram,
and instruction list.
Built-in data logging provides the ability to log data
points from the system I/O
directly into the PLC memory (see Figure 2). Access to data for IIoT
requires more advanced functionality for data
manipulation, storage, and delivery such as
database access, remote access, and email push
notifications. Enhanced security for the data
and application can be built-in with usernames
and passwords, but it is often implemented in
the next layer up from the controller, typically
at the human-machine interface (HMI) level.
The final feature listed, but sometimes the most
important one, is the price based on the average
system cost.
Figure 2: Higher end programmable logic controllers (PLCs)

work well in Industrial Internet
of Things (IIoT) applications due
to built-in data logging, data handling, and advanced communication capabilities.
Table 1: Typical features found in

industrial controllers: PLC, PAC, IPCs
Typical features
PLC
PAC
IPC
Serial communications
Good
Better
Best
Ethernet communications
Good
Better
Best
Standard protocol
communications
Fair
Better
Best
Custom protocol
communications
Good
Better
Best
Total I/O
Fair
Better
Best
Integrated motion
Poor
Good
Better
Integrated vision
Poor
Fair
Better
Integrated HMI
n/a
n/a
Very good
Memory (project and data)
Fair
Better
Best
CPU capabilities
Good
Better
Best
Simple programming
Best
Better
Fair
Enhanced programming
Poor
Fair
Better
Built-in data logging
Fair
Better
Best
Industrial Internet of Things

(IIoT) (access to data)
Poor
Better
Best
Enhanced security
Good
Good
Good
Price
Best
Better
Fair
CONTROL ENGINEERING
JANUARY 2017
| 29
COVER STORY selecting a controller

Industrial controllers applications
Based on the application requirements, certain control systems will function better than
others, but this determination will often vary
from individual to individual and for each job
(see Table 2).
Again, all of these rankings are subjective, and
individual results may vary
for each application.
PLCs replaced relays
Figure 3: With its extensive

range of features and capabilities, the programmable automation controller (PAC) covers all of the middle ground
between the programmable
logic controller (PLC) and
industrial IPC, with significant
overlap into both categories.
The best fit and most

common use for a PLC is
most likely in machine control applications. The PLC
was originally designed
for machines, and this certainly is its leading application today. Many machine
control applications are a
good fit for brick PLCs due
to this designs low cost, small form factor, and
ease of use. The PLCs low-cost hardware and
programming software, along with simple programming methods, make it a common choice
for original equipment manufacturer (OEM)
machine builders.
It is important to note that PLC and PAC
capabilities are converging. The gap in functionality is narrowing, which widens the range
of suitable applications for each controller
type. Many of the PAC capabilities discussed
below can therefore be realized in a high-end
PLC as well.
PACs widened control applications
Specify any control application, and it is

likely that the PAC would be a suitable controller. With simple data logging, the PAC allows
access to the data within the controller to optimize the factory.
With large I/O counts, expanded memory,
and enhanced data collection capabilitiesthe
Table 2: Industrial controllers

capabilities in typical applications
Typical Applications
PLC
PAC
IPC
Machine control
Best
Better
Fair
Basic and simple systems
Best
Better
Fair
Coordinated motion control
Poor
Better
Best
Integrated vision system
Poor
Better
Best
Process control and proportional-integralderivative (PID)
Fair
Good
Better
Distributed control
Fair
Good
Better
Batch control
Fair
Better
Best
30
JANUARY 2017
CONTROL ENGINEERING
PAC is a fit for a very wide range of applications (see Figure 3). The capabilities setting the
PAC apart from the PLC and placing it on an
IPC level are coordinated motion and integrated
vision capabilities.
The PAC often can handle multi-axis motion
control and dual axes or higher levels of coordinated motion. Some can perform circular interpolation if needed and control eight or more
axes of motion. The high-speed communication
in the PAC also allows it to communicate well
with todays smart vision sensors to pass realtime data back and forth. This also enables the
implementation of vision-guided motion functions within a PAC.
IPCs for process control applications
IPCs are well-suited for process control applications with extensive proportional-integralderivative (PID) and other algorithmic control
requirements. These more complex projects
often have very high analog I/O counts and usually need higher level math and advanced control
PID functionality.
With expanded data collection capabilities
and extensive communication options available,
distributed data collection and control applications are a good fit for IPCs. In many plants,
smaller skids systems are often distributed
throughout the facility and have their own PLCbased control, with these PLCs communicating
to a central IPC.
Hybrid control applications
While there is much overlap with PACs, IPCs

are well-suited for batch and continuous process
control and for automated machines working
together to form a process where raw material
enters, and a finished product exits. For these
applications, one controller system connects
with multiple expansion bases in multiple enclosures throughout the process. Multiple coordinated processors also may be used.
There are many considerations that go into
choosing the best controller, and the selection
process begins with the application. Many applications can be controlled by a PLC, a PAC, or
an IPCbut one type of controller usually fits
best. Taking the time to select the right type of
controller for the application will result in the
simplest, smallest, and least expensive control
system. ce
Jeff Payne is the automation controls group product manager at AutomationDirect. Edited by
Emily Guenther, associate content manager, Control Engineering, CFE Media,
www.controleng.com
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12/9/2016 4:25:01 PM
2016
Industrial Internet of Things &

Industrie 4.0
Turning research into insights makes for better business decisions
This study was conducted by CFE Media to gauge the engineers understanding and
current implementation of the Industrial Internet of Things (IIoT) and Industrie 4.0.
Respondents to the 2016 Industrial Internet of Things & Industrie 4.0 study identified
five key findings regarding their familiarity and implementation of the IIoT framework
and Industrie 4.0 platform.
According to the study, familiarity with the IIoT framework and the Industrie
4.0 platform has significantly increased since 2015; 79% of respondents
are very/somewhat familiar with IIoT, compared to 60% last year, and
53% are very/somewhat familiar with Industrie 4.0, compared to 33%
previously. More than half of respondents expect IIoT and Industrie 4.0
to improve connections between people, data, and machines at their
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COVER STORY controller selection criteria
How a PC-based
control system is an option
for every application
As automation technology accelerates in the industry, PC-based control is an option for
every application and for successful implementation for Industrial Internet of Things (IIoT)
and Industrie 4.0 initiatives.
MORE
ADVICE
KEY CONCEPTS
The benefits of a PC-based control
system.
PC-based control systems for IIoT
and Industrie 4.0.
How PC-based control systems fit
for every application.
GO ONLINE
For related links about PC-based
control systems, read this article
online. In the digital edition, click on
the headline or search the headline
for www.controleng.com.
CONSIDER THIS
What are the pitfalls to using PCbased control systems?
32
JANUARY 2017
ontroller
specification is the most
important stage of
the
development
process for every
industrial automation application. Historically, certain controllers were the de facto choice
for a particular machine design,
whether it was a programmable
logic controller (PLC) or programmable automation controller (PAC) depending on the area
and application.
These devices have performed adequately over the
years and have fostered an
if its not broken, dont fix
it mentality. However, as
advances in automation technology continue to
accelerate, PC-based control offers a unique set
of opportunities covering a wide range of application areas and is becoming a controller of choice
regardless of the application.
PC-based control system benefits
The biggest benefit of choosing a PCbased control system comes in the form of
superior scalability in hardware and software.
This offers engineers a clear and efficient migration path as machine and plant designs change
over time. For example, some manufacturers offer
a range of controller options from an entry-level
to an advanced reduced instruction set computer
(RISC) machines (ARM) processor, to a range of
multi-core controllers in multiple hardware formats, up to an industrial server equipped with a
36-core processor that enables many-core control.
These all run PC-based control software for a
range of functions, including PLCs, motion con-
CONTROL ENGINEERING
Figure 1: Beckhoff Automation

demonstrated HTML5-optimized
human-machine interface (HMI)
screens that can be displayed
on industrial displays and smartphones or tablets to show
machine speed, total operating
time, and good and rejected
parts. This smartphone shows
an HMI screen from a Cloudconnected groninger machine
at Pack Expo International 2016.
Beckhoff TwinCAT 3 PC-based
control software platform has
been expanded to give users
the ability to create Internet of
Things (IoT) and Cloud-connected
automation systems in the same
universal environment they program programmable
logic controllers (PLCs), motion control, robotics,
safety technology, and more. All images courtesy:
Mark T. Hoske, Control Engineering, CFE Media
trol, safety, human-machine interfaces (HMIs),

measurement, condition monitoring, and others
typically all on one device in the case of multi-core
controllers. Additionally, all but the multi-core
performance end of the product range can be
specified in multiple forms, whether it is DIN railmounted, cabinet-mounted, or integrated with an
HMI screen, among other options. HMI integration into an all-in-one device differentiates itself
over a PLC or PAC for PC-based control options,
as devices that integrate a screen for visualization
are few.
Solid-state storage options in the form of CFast
cards (also known as CompactFast) and solid-state
disks (SSDs) are also standard, reducing the number of moving parts and assuring high reliability
www.controleng.com
for critical applications. As an operation grows and

process needs rise, PC-based controllers easily can
be swapped for a more powerful model that uses
the same software platform.
This exchange typically entails a simple
exchange of a compact flash card from the old
unit with the new controller and a system restart.
Little or no programming is required (unless new
functions are added), a benefit of a software-based
automation system.
Using automation software to handle the
controls-specific tasks and running it on multipurpose, PC-based hardware has become a gamechanger for companies that seek a robust, flexible,
easy-to-use development environment and control
platform. For example, manufacturers offer control software that matches the PC-based hardware
with different performance levels to meet the individual needs of each application, whether special
features are called for in computer numerical control (CNC) motion and robotic kinematics or for
PLC functions.
In addition, the automation engineering environment is built into Microsoft Visual Studio,
making the software very familiar to the vast
majority of programmers and allowing for programming work to be shared among engineers
from various disciplines, such as traditional PLC
programmers, computer science programmers,
and information technology (IT) specialists. Reusing codes is a must and is something that control
engineers must consider when selecting a new
control platform.
Function blocks in IEC-61131-3 programming languages or other objectoriented programming often are available in application-specific libraries. Reusing code facilitates a
much shorter time to market and more flexible
machine designs for original equipment manufacturers (OEMs), system integrators, and end users.
PC-based control platforms for
IIoT implementation
Innovative engineers and company executives

are quickly determining that the implementation
of Industrial Internet of Things (IIoT) and Industrie 4.0 concepts is a logical next step to establishing more connected enterprises and is a necessary
consideration for future updates and development.
With a PLC or other closed hardware, adding IoT communication becomes a more difficult
proposition and typically requires the addition of
third-party hardware and software from IT companies to make everything work. With PC-based control, this type of connectivity was possible before
most major buzzwords of today were coined.
www.controleng.com
Figure 2: Some vendors suggest that PC-based multi-core controllers that also
run Microsoft Windows software, such as the Beckhoff Automation CX5100 series
Embedded PC (right), are easier to connect and communicate to Industrial Internet
of Things (IIoT) mobility applications, as shown at Pack Expo International 2016.
Beckhoff also demonstrated the upcoming EK9160 IoT Bus Coupler (not shown)
that connects Beckhoff EtherCAT I/Os with the Microsoft Azure Cloud directly,
without the need for a specific control program. The coupler offers simple and standardized integration of I/O data with cloud-based communication and data services.
More importantly, connectivity can be

accomplished with little or no additional hardware because Internet and Ethernet connectivity has been built into PC-based control
platforms for decades. Even if an operation isnt
quite ready to make the jump into the waters of
IIoT and Industrie 4.0, PC-based control provides the most logical control platform with an
unobstructed migration path to add higher levels
of connectivity today or at any time in the future.
The already high demands for control systems
will increase. As plant engineers and machine
builders ask controls vendors to provide more
functionality and connectivity within a comparable price point, flexible and scalable PC-based control systems represent the most cost-effective and
robust option. ce
Reusing codes
is a must and
is something
that control
engineers must
consider when
selecting a
new control
platform.
Eric Reiner is an industrial PC market specialist at

Beckhoff Automation. Edited by Emily Guenther,
associate content manager, CFE Media, Control
Engineering, eguenther@cfemedia.com.
CONTROL ENGINEERING
JANUARY 2017
| 33
COVER STORY control system selection
Choose the right control system

Choosing between a programmable logic controller (PLC) or a distributed control system (DCS)
depends on the type of project and plant. Benefits of each differ, depending on the application.
A
MORE
ADVICE
KEY CONCEPTS
Programmable logic controllers
(PLCs) are mainly designed for discrete
industries, and distributed control
systems (DCSs) are mainly designed
for process industries.
PLCs are best used for short-term
applications while DCSs are best in
long-term applications.
Several methods can determine if a
PLC or a DCS is best for an operation.
GO ONLINE
See related stories online at
www.controleng.com.
CONSIDER THIS
How should you determine whether
to use a DCS or PLC for an operation?
successful automation project requires

automation and design engineers to
evaluate application requirements
and choose the most effective control system platform. These decisions
will have a long-term impact on a facilitys operational performance for 25 years or more years in
some cases. Most control system decisions come
down to choosing a programmable logic controller (PLC) or a distributed control system (DCS). In
some cases, one option is clearly better for a plant
while in others the option is not as easy. Many factors are involved in selecting the control system that
will help achieve short- and long-term goals.
Control system platforms influence how the
automation system will meet the needs for optimizing production, sustaining reliability, and obtaining
data. A lack of foresight in choosing a control system also can hinder expansion, process optimization, user satisfaction, and a companys profits.
Apart from basic criteriasuch as how to control the processthe design team must recognize
considerations such as installation, expendability,
maintenance, and upkeep, among others.
While PLCs might be cost-effective for the time
being for a small facility, a DCS provides a more
economical expansion with a potential return on
the initial investment.
A PLC is an industrial computer that is built to

control manufacturing processes such as robots,
high-speed packaging, bottling, and motion control.
In the last 20 years, PLCs have gained functionality and provided benefits to small plant applications
and skid units. PLCs are generally self-contained
islands of automation that can be integrated so they
can communicate with one another. The engineering required for integration requires some degree of
mapping between controllers because each PLC has
its own database. This makes PLCs a good fit for
small applications that are unlikely to be expanded.
A DCS distributes controllers throughout the
automation system and offers a common interface, advanced control, a systemwide database, and
information that can be shared easily. DCSs are traditionally used in process applications and larger
plants and are easier to maintain for large system
applications throughout the plants lifecycle.
Application determines the platform
PLCs and DCSs generally are suited for discrete

or process manufacturing. Discrete manufacturing facilities, which usually use PLCs, are composed of separate production units that generally
assemble components, such as labeling or fill-andfinish applications. Process manufacturing facilities, which usually use DCSs, automate continuous
Figure 1: The DCS

architecture with
a single database
approach allows
users to easily maintain and operate the
system from centralized workstations.
All graphics courtesy: Emerson
34
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
and batch processes and implement formulas composed on ingredients rather than pieces, and their
output is measured in bulk. Large continuous
process facilities, such as refineries and chemical
plants, use DCS automation. Hybrid applications
generally use PLCs and DCSs. To choose a controller for an application consider process size, expansion or modification plans, integration needs,
functionality, high availability, and return on
investment (ROI) over the facility lifecycle.
Process size: How many input/output (I/O)
points are needed? Smaller systems (<300 I/O
points) might have smaller budgets, which makes
PLCs a better fit. DCSs dont scale down as easily
and function better in larger plants. DCSs are easier
to manage and upgrade because they have one database; changes can be applied globally.
Modification plans: Small processes can use
PLCs, but if that process is expanded or modified,
more PLCs and databases need to be added and
independently maintained. This is a time-consuming process that leads to errors. DCS upgrades are
easier to perform, and aspects such as user credentials are managed from a central hub, which results
in easier upkeep and maintenance (see Figure 1).
Integration needs: For a skid that stands alone,
a PLC is ideal. When multiple PLCs are brought
into a plant, interconnections are required. These
can be difficult to create and often require data
mapping through communications protocols. Integration can be achieved, but users might run into
challenges when changes are made to a PLC that
can result in two PLCs that no longer communicate as intended because the data maps have been
impacted. Mapping is not required with a DCS, and
configuration changes are a

simple process; the controllers
are native to the system.
Functionality:
Some
industries and facilities
require historians, streamlined alarm management,
and a central control room
with common user interfaces. Some require management execution system
(MES) integration, advanced control, and asset
management. The DCS has these applications
built in (see Figure 3), which makes it easy to add
to an automation project without separate servers or added integration costs. This is more costeffective, increases productivity, and lowers risk.
High availability: For high process availability
a DCS provides redundancy options (see Figure 2).
Lifecycle ROI: Facility expectations vary across
industries. PLCs provide excellent ROI for small
and nonexpanding processes that dont require integration with other process areas. A DCS may have
high installation costs, the full lifecycle costs and
resulting increases in production and safety pay for
themselves over the the systems lifetime.
Figure 2: For strong

process availability,
redundancy is important to long-term
operation. Efficiency
and ease of achieving
redundancy are key to
maintaining budgets.
Automation strategy
Balancing short-term needs with long-term

vision is critical for operational certainty and
improve plant operations and maintenance. ce
Bob Halgren, DCS strategy manager, Emerson.

Edited by Chris Vavra, production editor, Control
Engineering, CFE Media, cvavra@cfemedia.com.
Figure 3: For functionality listed here,
each platform presents unique database requirements.
www.controleng.com
CONTROL ENGINEERING
JANUARY 2017
| 35
INDUSTRIAL SYSTEMS real-time communications
What does TSN and real-time

Ethernet data mean for the
future of industrial systems?
Avnu Alliance members explain how real-time communications enabled by Time Sensitive
Networking (TSN) will strengthen the future of industrial systems.
he Industrial Internet of Things (IIoT)

brings the opportunity to create smart
systems that share data between
devices across the enterprise and in the
cloud. As interest in IIoT and Industrie 4.0 continues to grow, more designers, engineers, and end-users are looking to Time Sensitive
Networking (TSN)--a set of standards under revision from the Institute of Electrical and Electronics Engineers (IEEE)-to solve the need to process
raw data in a timely fashion, reduce latency,
increase robustness, and provide a foundation for
more advanced manufacturing and product models where data can be more flexible and shared
between layers of the control system.
To support these new capabilities of an IIoT
infrastructure and to connect network devices,
there is a need for an interoperable system that
allows multiple manufacturers, protocols, and organizations to share the same TSN network. To prepare for this, Avnu Alliance selects and certifies
a set of underlying mechanisms to meet a given
markets requirements, creating a common infrastructure that others can build on to enable convergence between operational technology (OT) and
information technology (IT). This convergence
increases connectivity to industrial devices and
MORE
ADVICE
KEY CONCEPTS
Avnu Alliances role in educating
manufacturers and end users.
The future of industrial networking.
Standard Ethernet and TSN technology.
GO ONLINE
For related links about timesensitive networking, read this article
online. In the digital edition, click on
the headline or search the headline
for www.controleng.com.
Read more about time-sensitive
networking online.
Also see www.avnu.org.
Future Industrial
Protocol
IEEE 1722
PROFINET
IEC 61850
ODVA EtherNet/IP
OPC-UA pub/sub
TM
CONSIDER THIS
Would having interoperable TSN
industrial networking devices ease
system integration?
IEEE/IETF defined, Avnu selected and certified common network services

Market-specific interoperability profiles for time synchronization, quality of service, network configuration, etc.
Certifiable open source software implementations with standard APIs, hardware reference designs, etc.
Figure 1: Multiple applications can use Avnu Common Network Services. All graphics courtesy: Avnu Alliance Industrial Group
36
JANUARY 2017
CONTROL ENGINEERING
enables a faster path to new business opportunities

including Big Data analytics and smart, connected
systems and machines. Avnu Alliance is an industry
partnership that fosters and develops an ecosystem
of manufacturers providing interoperable devices
for industrial networked systems.
Control Engineering (CE) caught up with
several Avnu Alliance members to ask how the
IIoT is affecting industrial networks and what
TSN means for the future of industrial systems.
Todd Walter is chief marketing manager, National
Instruments and Avnu Industrial Segment chair;
Ludwig Leurs is director of Ethernet convergence
at Bosch Rexroth; Anil Kumar is principal systems
engineer of the Internet of Things group at Intel;
Paul Brooks is business development manager at
Rockwell Automation; Bogdan Tenea is product
specialist at Ixia; and Paul Didier is industry solutions architect at Cisco.
CE: How has the evolution of Ethernet
changed the approach to designing industrial
control systems?
Ludwig Leurs: Standard Ethernet has evolved
to enable next generation control systems. With
this, recent work by IEEE 802 LAN/MAN Standards Committee (LMSC), the Internet Engineering Task Force (IETF), and other standards groups
has extended the ability to operate time-sensitive
systems over standard Ethernet networks, supporting diverse applications and markets including professional audio/video, automotive, and industrial.
These standards, driven primarily by the IEEE 802.1
TSN task group, define new mechanisms for creating distributed, synchronized, real-time systems
using standard Ethernet technologies that will allow
convergence of low-latency control traffic and standard Ethernet traffic on the same network.
TSN supports real-time control and synchronization, for example, between motion applications
www.controleng.com
and robots, over one Ethernet network. TSN can at

the same time support other common traffic found
in manufacturing applications, driving convergence
between IT and operational technologies. TSN
is not a disruptive technology, it enables existing
industrial real-time control applications to coexist
and interoperate, such as the new OPC UA publisher/subscriber model currently being finalized in
the OPC Foundation. As Avnu has shown success
in audio/video applications, it will be helpful being
able to reuse this technology in modern machines
using video cameras in control loops.
CE: With networks becoming increasingly
congested with IIoT data, how does TSN ensure
that data gets communicated to make IIoT viable
to help users?
Anil Kumar: TSN promises a world of
smarter, hyper-connected devices, and infrastructure. Manufacturing machines, transportation systems, and the electrical grid will be outfitted with
embedded sensing, processing, control and analysis
capabilities. Though much of the data collected by
industrial sensors and control systems in an IIoT
application are not time-sensitive, there will also be
a great deal of mission-critical, time-sensitive data
that must be transferred and shared within strict
bounds of latency and reliability.
Requirements of TSN such as a common clock
for transmission scheduling, latency provisions,
reserved bandwidth and redundancy make it so
that TSN ensures precise time synchronization to
support synchronization of multiple data streams.
Large data sets from machine vision, 3-D scanning, and power analysis can put a strain on network bandwidth. TSN will support full-duplex
standard Ethernet with higher bandwidth options
such as 1 Gb, 10 Gb, and even the 400 Gb version
in IEEE 802.3. It also offers top-tier IT security
provisions and interoperability with scalability
that can grow into large systems. TSN can also
integrate with existing brownfield applications
and standard IT traffic and is future-proof, as it is
constantly evolving.
CE: How will the new generation of Ethernet
with TSN features improve over previous generations of the standard?
Paul Brooks: TSNs value is derived from
simplifying convergence and increased connectivity, unlocking the critical data needed to
achieve the IIoT promise of improved operations
driven by Big Data analytics. Designers can take
advantage of the advancements in processing,
www.controleng.com
communications, software, and system design

originating from the consumer world with a standard that evolves while providing precise timing.
For industrial markets specifically, these standards support the ability to simplify development
and deployment of distributed, synchronized,
control systems commonly found in a variety of
industrial applications including machine control, factory automation, power generation and
distribution, oil and gas exploration, etc. Many
of todays generation of control applications are
deployed using nonstandard network interfaces
and infrastructure. Limitations to Ethernet have
caused a fragmentation and lead to the creation
of variants of Ethernet that include real-time performance to meet the needs of measurement and
control applications. These variants often modify
hardware and infrastructure components of the
Ethernet stack to provide guarantees on behavior.
These modifications provide the latency and bandwidth reservations needed for control. However,
because they required modification of hardware
they are no longer interoperable with standard
Ethernet, and they are much harder to access on
the network, if at all.
TSN promises
a world of
smarter, hyperconnected
devices, and
CE: How are Avnu Alliance and its members

driving this next-generation standard?
Todd Walter: Avnu Alliance is a nonprofit
member run organization promoting, educating,
and enabling companies to create devices that provide reliable, synchronized deterministic networks.
Our focus is the creation of an open, interoperable
ecosystem through interoperability verification and
testing across broad markets. As the capabilities to
Ethernet are updated with new standards, Avnu
Alliance provides a community to discuss, collaborate, certify, and promote the continually evolving
network capabilities that enable the convergence
between OT and IT.
Avnu has collaborated with the IIC to develop
the worlds first TSN testbed to showcase the value
to the standards and the ecosystem of manufacturing applications, including the ability for IIoT
to incorporate high-performance and latencysensitive applications. We are hosting the testbed at
National Instruments.
CE: Have there been any recent advancements in TSN technology that you can share?
Bogdan Tenea: It was actually just back in
September, at the IEEE Automotive Ethernet &
IP Technology Day, that a couple of Avnu members demonstrated for the first time a new IEEE
CONTROL ENGINEERING
infrastructure.
JANUARY 2017
| 37
INDUSTRIAL SYSTEMS real-time communications

industrial systems. At the physical layer, coming up with more Ethernet variants: lighter copper cabling (such as single twisted pair), longer/
shorter distances (10s to 1000s of meters), and
more PoE options, like lower power for intrinsically safe environments. This enables deployment in more harsh, industrial environments. In
the IETF DetNet working group, we are extending those TSN deterministic capabilities over
larger, scalable networks to handle much larger
systems. We we also will bring TSN into standard, open wireless networks.
All this dovetails well with key initiatives in
general networking, including the ongoing efforts
to bring higher bandwidths to more devices. But
I would like to especially point out the push to
automate network configuration and management often referred to as Software-Defined
Networks.
Figure 2: This image shows

a time-sensitive networking
(TSN) Testbed at IoT World
Congress in October 2016.
TSN standard called preemption. There, the test

equipment from Ixia proved interoperability and
measured the performance improvements of prototype devices supporting this new technology.
Preemption (IEEE 802.1Qbu/802.3Qbr) [Standard for Local and Metropolitan Area Networks
Media Access Control Bridges and Virtual Bridged
Local Area Networks-Amendment: Frame Preemption] is a new addition to the Ethernet standard from the IEEE that allows a high-priority
frame to interrupt a lowpriority frame in transmission, minimizing latencies in the high-priority traffic. In industrial automation control system (IACS)
applications, preemption can further convergence
of multiple networks of differing technologies into
one Ethernet and IP infrastructure, enabling selforganizing plant operations and order controlled
production. By highly decreasing the impact of
lower-priority traffic on important traffic, both
types of traffic can be mixed on the same link.
CE: What needs to happen with network
infrastructure to support future demands from
industrial systems?
Paul Didier: With TSN, we have established a key building block for industrial vendors
to now build IoT-ready devices and applications
that use a converged network. The standards still
are evolving here. We still have to finish standards on: resiliency, no packet-loss over multipathed networks; the ability to police traffic to
further protect the TSN traffic; pre-emption, the
ability to break up large packets and more.
But beyond the TSN work, we are working
on numerous other challenges directly related to
38
JANUARY 2017
CONTROL ENGINEERING
CE: What can we expect to come from Avnu

and TSN in 2017?
Walter: As the latest generation of projects
finish and become formal parts of the standard,
we are seeing increased interest from nearly all
vendors. The first TSN industrial products were
available to select customers in 2016 including controllers from National Instruments with
Intel TSN silicon and drivers as well as Cisco
TSN switches. In 2017, we will see more products
from multiple Avnu members. The fact that this is
based on the open Ethernet standards means that
technology adoption benefits from the investment
of all the companies and brands supporting it and
is not limited by one companys business plan or
future decisions on how they are going to develop
and support the technology. Manufacturers within the industrial market benefit from Avnus collective multi-industry experience and networking
expertise to expedite advanced networking implementations ultimately leading to a faster path to
market.
As the standards and networks continue to
evolve, so does Avnus work to define and certify the
standard foundation. This eventually will include
mechanisms such as frame preemption, redundancy, ingress policing, and security. In addition,
Avnus defined foundation will continue to support
additional capabilities, including support for multiple IEEE 1588 profiles, guidelines for scaling to
very large network architectures, and aggregation/
composition of multiple networks into one TSNenabled network domain. ce
Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media,
www.controleng.com
VFD automation specification
Four questions to ask

when selecting a VFD
To select a variable frequency drive (VFD) consider the application, power source characteristics, and
other safety and maintenance aspects to ensure that a production plants operations remain smooth
with minimal downtime.
roduction plants need more automation control and increased production

speeds. It is common for a variable frequency drive (VFD) to control threephase motors in automated process plants
as well as commercial buildings. It is important that
the VFD matches application needs. Buyers and
specifiers of VFDs should ask specific questions
before selecting a VFD for an application.
1. What is the application?
Applications can be categorized as one of three

types: variable torque, constant torque, and constant horsepower. Reference tables in drive manufacturer catalogs and the internet can provide users
with guidance on the torque and power characteristics required for specific applications. Table 1 online
provides a few examples of each of these types. The
most significant factor in this step is to match the
load characteristic to the drive. The drive should be
selected to meet or exceed the motors need for current in a steady-state average mode and overload,
which is typical of a demanding start.
2. What are the VFDs power source

characteristics?
Once the application has been defined, the next
step is to identify the input voltage, frequency, and
power distribution configuration. In North America, the input is usually ac, but some applications
require dc. Low-voltage input options typically will
be 115 V ac, 208 to 230 V ac, 380 to 480 V ac, or
575 to 600 V ac, and as high as 690 V ac. Typical
input frequencies are 50 or 60 Hz. While this isnt
common, ac drives are specified to work from dc
sources, which broaden the range for alternate technologies and more demanding system applications.
3. What enclosure is needed?
Ensuring a proper enclosure is critical because

it increases the drives longevity and provides
protection. Many drives are part of bigger automation platforms and have space reserved in
clean, air-conditioned control rooms. This puts
less ambient stress on the equipment. Chassis or
www.controleng.com
minimally protected products are available from

most drives manufacturers for just this purpose.
Most individual motor controllers on their own
in the field are subject to fluctuating conditions.
Understanding where the drive will be installed is
key to a long service life. UL or NEMA types 1,
12, and 4 represent most of the standard protection ratings that may be needed. Consider settings
in Table 2 online. Operation outside these ranges
is possible, and each drive manufacturer can provide derating factors to allow proper selection of a
larger product for more demanding applications.
Custom-engineered options may be possible.
4. Is the drive compatible with the process?
For this step, users, machine builders, and system integrators need to ask two process questions:
Is feedback required? Define the demands and
expectations for the motor in the applications.
Many drive applications are considered process
regulators rather than speed regulators. Embedded memory, faster processors, and input/outputs
(I/Os) allow drives to control various processes.
These might include a transducer wired into the
drive to maintain a level in a vessel using a PID
application or a winder application that uses several encoders controlling multiple drives to calculate correct diameters and speeds. Regardless of
the process type or the signals being measured
pressure, flow, or temperaturethey still are used
to control the drives output to the motor.
What kind of communication is required? Communication is a key part of many applications. In
some cases, a useful display that helps the operator
affirm that the process is ready is all that is required.
Other communications from the drive include analog and digital outputs. Statistical data on the conditions controlled by the drive may be needed, which
makes fieldbus communications a good option.
Control from a data collection system (for building
automation applications) is also possible. ce
Tim Park, senior applications engineer, Danfoss.
CONTROL ENGINEERING
MORE
ADVICE
KEY CONCEPTS
Users should select a variable
frequency drive (VFD) that matches
their application
Applications can be categorized as
variable torque, constant torque, or
constant horsepower.
Users need to consider communication protocols and maintenance
strategies when selecting a VFD.
GO ONLINE
Read this story online for 2 tables,
application photo, more information,
and additional articles on VFDs at
www.controleng.com.
CONSIDER THIS
What other questions should users
ask when selecting a VFD?
JANUARY 2017
| 39
TECHNOLOGY ADVANCES VFD design
The fundamentals of
matrix variable frequency
drive technology
Providing cost, space, and energy efficiency for VFD applications.
ariable frequency drives (VFDs),

also known as variable speed drives
(VSDs), and sometimes inverters,
have benefited from many advancements since their introduction in the
1970s. During most of that time, however, the
basic design of the drive remained the same, with
improvements in performance, size, and cost coming mainly from advances in the drives semiconductor components.
From the beginning, VFDs have been used to
control the speed of electric motors, which consume approximately 25% of the worlds electrical
energy in industrial and commercial applications.
By definition, VFDs enable users to operate a
motor at any commanded speed, as opposed to
running across-the-line at a fixed speed. This variable speed control improves energy efficiency and
lessens the wear and tear on mechanical couplings,
such as gears, belts, and pulleys.
Conventional VFDs
Despite the advantages of energy savings and

extended equipment life, VFDs at times also can
have an undesired effect on electrical equipment in their proximity. By nature of their conventional design, VFDs are non-linear electrical
loads; that is their input current does not follow the same sinusoidal waveform as the supply voltage.
A conventional VFD rectifies incoming alternating current (ac) voltage to charge capacitors
and establishes a direct current (dc) bus voltage level. The drive control then generates two
internal waveforms a carrier and an output.
The carrier is a triangle waveform at a frequency
much higher than is used to drive the motor,
typically around 8 kHz to 15 kHz. The output
frequency is a simulated sine wave at the frequency required for the desired motor speed.
The VFD supplies voltage to the motor at the
output frequency by using pulse width modulation (PWM). Because the source for the output voltage is dc from the bus, the VFD uses
its insulated gate bipolar transistors (IGBTs)
to create a simulated output voltage sine wave
by turning on the dc voltage when the carrier
level is less than the output frequency level and
MORE
ADVICE
KEY CONCEPTS
The benefits of VFDs with a matrix
design.
Comparing VFDs with a conventional or matrix design.
The design and operations of VFDs
with a matrix design.
GO ONLINE
For related links about VFDs, read
this article online. In the digital edition, click on the headline or search
the headline for www.controleng.com.
CONSIDER THIS
What are other low-harmonic solutions for industrial applications?
40
JANUARY 2017
Figure 1: The following graph illustrates the total current and the sum of the first and fifth harmonics.
All graphics courtesy: Yaskawa America, Inc.
CONTROL ENGINEERING
www.controleng.com
turning it off when the carrier is greater than

the output frequency level.
The motors inductance filters the PWM
waveform so it operates on the pulses as a simulated sine wave. During operation, the VFD varies the timing and width of the pulses to provide
the correct frequency to drive the motor at the
speed needed for the load.
As the motor consumes energy, it draws
down the dc bus charge, which then is replenished from the rectified incoming ac voltage.
Although the bus voltage level varies with the
load, the dc bus draws its replenishment current only at the peaks of the rectified sine wave.
These current pulses, while keeping the dc bus
charged and the drive operational, can lead to
some problems with current harmonics.
Harmonic currents occur at frequencies in
multiples of the fundamental frequency, 60 Hz
in the United States. Figure 1 shows the sum
of the fundamental (first) and fifth harmonic
currents. In practice, additional harmonics distort the current waveform further, although to
a lesser degree. The harmonic current (in this
case fifth harmonic x 60 Hz = 300 Hz) cannot
be used for real work and will be converted
into wasted heat or mechanical energy.
Harmonics can cause cables to overheat,
circuit breakers to trip, and stress on upstream
transformers. Significant current harmonics
can have a negative effect on the sources ability
to provide clean power, which in turn results in
voltage distortion, equipment disruption, and
power company fines.
VFD matrix design and operation
A relatively new VFD design, on the other

hand, obviates the dc bus by using nine bi-directional IGBTs in a matrix arrangement to generate the variable frequency ac output directly
from the ac input. With no dc bus to charge, the
associated non-linear input current draw can be
eliminated. Figure 2 shows the matrix topology.
For drives that use a matrix design, any input
phase can be connected directly to any output
phase at any time. The key to a drives matrix
operation is its ability to turn the bi-directional
switches on and off at the correct times to generate the proper output voltage and frequency
required to operate the motor.
The control built into the VFDs matrix
design continually monitors the voltage difference between each of the three input phase
voltages.
These phase voltage differences provide the
VFDs matrix design with a continuous range of
www.controleng.com
voltages that are available to send to the motor,

along with the ability to use the nine IGBTs to
switch any input phase to any output phase at
any time. Also using PWM, they generate the
proper voltage at the proper frequency to drive
the motor as needed for the load.
In addition, the range of voltages available
enables the VFDs matrix design to build its
pulses in steps to reduce the effects from steep
voltage rises on motor-bearing currents and
reflected waves in long motor leads.
Figure 2: The illustration

shows the topology of a
variable frequency drive
with a matrix design.
Significant current harmonics can have a negative

effect on the sources ability to provide clean power,
which in turn results in voltage distortion, equipment
disruption, and power company fines.
In addition to the ultra-low harmonics and

near-unity power factor, the VFDs matrix
design also provides energy savings through
regeneration. When a motor is being driven by
a load, as opposed to driving the load, it acts as
a generator, sending voltage back to the VFD.
Examples include applications such as pump
jacks, where the load oscillates between motoring and regeneration, and downhill conveyors
CONTROL ENGINEERING
JANUARY 2017
| 41
TECHNOLOGY ADVANCES
VFD design
Figure 3: This illustration shows a comparison between a conventional variable frequency drive (VFD) with a Yaskawa Matrix VFD
for power regeneration.
on energy
that are in a continuous regenerative state (see

Figure 3). In conventional drives, dynamic braking resistors can be used to divert the regenerative energy away from the VFD and prevent
a dc bus over-voltage condition. Drives with a
matrix design using nine bi-directional IGBTs
enable the regeneration voltage to be directed back to the supply to be credited against the
users power bill.
The main benefit of VFDs is to enable a
fixed-speed motor to operate at variable speeds.
However, some applications require full speed
for significant periods of time. In these cases,
the matrix design can close the appropriate
IGBTs to provide a direct connection between
input and output to the motor, thus maximizing
efficiency without requiring conventional VFDs
to use contactors to bypass the drive.
This mode also prolongs the life of the VFD
by allowing all the IGBTs to rest while maintaining at a steady on/off position.
savings.
VFDs for monitoring
Some VFDs
with a matrix
design can
monitor power
in several ways
to give instant
feedback
Some VFDs with a matrix design can monitor power in several ways to give instant feedback on energy savings. When provided with the
dollar amount per kWh billing rate, the display
on the VFD can show the following information
on request:
Power output
Power consumption
Regenerative power
Power saved
Power bill.
42
JANUARY 2017
CONTROL ENGINEERING
Comparing VFDs with a matrix

or conventional design
There are also other means to mitigate

the harmonics of VFDs. These include active
front-ends and multi-pulse transformers,
which require significant additional components in combination with the VFD, all
of which mean added bulk, cost, and wiring connections. The VFD with a matrix
design accomplishes low harmonics all within the drive three wires in, three wires out.
Though VFDs with a matrix design are priced
higher than conventional VFDs, prices are usually comparable or less expensive than other lowharmonic solutions.
VFDs with a matrix design are available in a
wide range of voltage and horsepower ratings,
typically up to 100 HP at 240 V and 350 HP
or larger at 480 V. Look for the same Underwriters Laboratories (UL), Canadian Standards Association (CSA), CE, and Restriction
of Hazardous Substances Directive (RoHS) certifications and support for induction, surface
permanent magnet, and interior permanent
magnet motors.
VFDs with a matrix design provide all the
features and functionality users have come
to expect from a conventional VFD, plus the
added advantages. With heightened requirements for sustainability and compliance to
IEEE 519-2014, matrix VFDs provide a costefficient, space-efficient, and energy-efficient
means for applications. ce
Larry Gardner, HVAC drives product manager,
Yaskawa America, Inc. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.
www.controleng.com
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ROUNDTABLE system integration
System integrators help

with IIoT preparation, adoption
Get tips on the Industrial Internet of Things (IIoT) and learn how system integrators can help:
CFE Medias interviews of three representatives from the 2017 System Integrators of the Year.
CFE Media
MORE
ADVICE
KEY CONCEPTS
Manufacturers show interest
and uncertainty related to ndustrial
Internet of Things (IIoT).
System integrators can work as
advisors and mentors.
GO ONLINE
Read this story online for a link
to the full roundtable discussion at
www.controleng.com and video.
CONSIDER THIS
How will IIoT influence you in 2017?
interviewed three representatives from the 2016 System Integrators of the Year
Abhijit Jog, vice president of projects, Panacea
Technologies; Shawn Campion, president, Integro
Technologies; and Jack Woelber, president, Interstates Control Systemsabout their views on these
topics as well as what they see in the future for their
companies, for integrators, and for manufacturing.
around the IIoT space and as that market matures

and hopefully we can help our customers with what
makes sense for them to get involved in and what
doesnt and maybe what technology they can use to
make it beneficial for them.
CFE Media: What are your customers starting

to talk to you about regarding Industrial Internet
of Things (IIoT)?
Campion: I believe it can happen very quickly.

I think it comes down to the capital expenditures
they want to do for a given year. In our case, being
a machine vision integrator, the image storage we
require for the data storage is much more substantial than other types of data collection methodologies, so our investments are much higher. I think
for core data acquisition for your number crunching, it can happen within a years time and be fully
instrumented within a facility if they make that
commitment.
Jog: Our customers have shown a lot of interest in the IIoT. We have seen a lot of interest in it but
we are still in the preliminary design phase for a lot
of these projects and were asking them to proceed
with a little caution until the IIoT security aspects
and other aspects are worked out.
Campion: A majority of the discussions we
have are at a very high level with the chief intelligence officer (CIO) of the companies to work
through various security options and how we can
penetrate firewalls to gain that information and also
gather it and do this statistical analysis.
Woelber: Were seeing the same thing and in
addition to that the market is just continuing to
expand and were seeing a lot more around that so
weve taken on some opportunities to do some R&D
CFE Media: How fast should IIoT happen in

manufacturing?
CFE Media: How does the cloud work with

IIoT and what are the potential risks?
Jog: The cloud is the game changer, but the
concerns are around the IIoT devices that people
are putting out. In the manufacturing environment,
its not some website going down. We have people
who depend on us for the infrastructure, for the
electricity and its important for us to protect and
its our responsibility to do so. Are devices themselves secure? With manufacturers putting IIoT
devices out, even if one device in your field network
has the potential to bring down the whole network
in the manufacturing, that would result in disastrous consequences.
CFE Media: How do we move past security
concerns with IIoT implementations?
System integrators offer insights in a Control Engineering and Plant Engineering

video. From the left are CFE Medias Bob Vavra followed by representatives of the
firms named as the 2017 System Integrators of the Year: Abhijit Jog, vice president of
projects, Panacea Technologies; Shawn Campion, president, Integro Technologies; and
Jack Woelber, president, Interstates Control Systems. Courtesy: CFE Media
44
JANUARY 2017
CONTROL ENGINEERING
Woelber: Interstates has a group that deals

with cybersecurity. Being able to keep information
secure within the organization is going to be critical, so we think the infrastructure within the facility is going to be critical for the cybersecurity piece
of IIoT. ce
www.controleng.com
INSIDE PROCESS DCS/PLC migration
Six action items for

an aging DCS/PLC
Plant and operations managers need to be aware that their distributed control systems (DCSs) and
programmable logic controllers (PLCs) could be obsolete and they should take appropriate steps to
deal with the problem. Six immediate action items for an aging system are highlighted.
lant, operations, facility managers, or

C-level executives of process manufacturing facilities likely dont get deeply
involved in the status of control systems and infrastructure. Interaction
with the control system may be periodic updates
that are delivered by an engineering manager,
which is perfectly reasonable. However, it is typically in their best interest for you to be of the
opinion that they are doing a great job keeping
your plant online and producing, so the updates
that you receive may be rosier than they should
be. Because of that, managers may not be getting
the entire story, especially if you have an aging
control system.
Managers may not be hearing that their
team is struggling with equipment failures,
worn-out cables, obsolete operating systems
on their consoles, and especially equipment
sourcing. Weve encountered equipment sourcing situations that definitely should have raised
red flags, such as using remanufactured parts
websites and even eBay.
Due to the staff s resourcefulness, the facility hasnt had any serious downtime yet, but the
clock is ticking. Budgets are always a constraint
and capital expenditures may be tight, especially
for full distributed control system (DCS) or programmable logic controller (PLC) replacements,
which are often multi-million dollar investments.
That investment, though, is nothing compared to
the cost if the production facility went down and
could not recover for a week or more.
Whats even more concerning than that is there
are many facilities that are unprepared for system failure or obsolescence, which can have catastrophic consequences. Operations, facility, or
engineering managers need to begin preparing for
migration of your control system from a legacy system to current and supported architectures.
Good information is critical to success. Discuss the situation with the controls team and
potentially a trusted systems integrator. In the
meantime, there are six things the staff can do to
www.controleng.com
help to prepare until there is a plan in place and a

budget has been approved.
For an aging DCS/PLC, these six action items
should be done immediately:
1. Backup
2. Get copies of all software license files
3. Update system drawings
4. Check available spare parts
5. Make a wish list
6. Develop a functional specification
for a migration plan.
Remember the famous words of Ben Franklin:
By failing to prepare, you are preparing to fail.
MORE
1. Backup
The best method for obtaining a backup is to

take an image of the machines, which can be difficult if the operating system is old. There are several software packages available to perform this
task, but get it done. Do it soon, regardless of
what is chosen.
2. Get copies for all software

license files
Make copies of all license files. Its not

uncommon to run into a situation where
the supervisory control and data acquisition
(SCADA) or other types of software are not
technically licensed to the end user. The software was still in the integrator or original equipment manufacturers (OEMs) nameor, even
worse, in another customers name. When you
have copies, check with the vendor to ensure the
licenses are valid. If they are not, make contact
with whoever sold the program because thats
another set of problems.
ADVICE
KEY CONCEPTS
There are many facilities that are
unprepared for system failure or obsolescence, which can have catastrophic
consequences.
A well-done functional specification
will allow the company to plan the
best method with the requirements
that are important to your company
and specific to the system.
The functional design specification
is a very important and critical part of
this entire process.
GO ONLINE
Link to additional online resources,
DCS/PLC migration, and related content at www.controleng.com/archives,
under January 2017.
CONSIDER THIS
Is the distributed control system
(DCS) or programmable logic controller
(PLC) running the processes in your
plant nearing obsolescence?
CONTROL ENGINEERING
JANUARY 2017
| P1

3. Update system drawings
Begin
developing a
list of priority
issues that you
would change,
if you could.
Be sure to
include
operations
and
maintenance
as well.
This includes panel drawings, process and

instrumentation diagrams (P&IDs), network
layout and/or one-line diagrams (also known
as single-line diagrams), etc. This is the most
time-consuming task, but it will pay extreme
dividends in the long run. If possible, get electronic copies of your panel drawings and have
someone (an engineer, a maintenance tech, or
intern) go through all of the input/output (I/O)
to ensure the drawings are labeled correctly and
all of the wires are marked with wire numbers.
If there are decommissioned I/Os, then disconnect them and label them as such.
Please take proper precautions in accordance with appropriate regulations. Also, watch
for old network cables as they are prone to
come loose. This can cause the process to stop
or shut down. As much trouble as it may seem,
this exercise will help facilitate the crossover
drawings during a future upgrade. This also
will be greatly appreciated by your maintenance team while they troubleshoot the aging
system prior to an upgrade. If there arent
drawings available, take detailed pictures and
create termination drawings. As long as they
are accurate, they will suffice.
4. Check available spare parts
Immediately review available spares and

ensure that you have spare parts for all critical
components. The problem is that because the
system is old, or potentially obsolete, the cost of
the parts may be greatly elevated. So, take into
consideration how long the plant will be running

on the old system and when you will start your
migration. A phased-in approach will provide
spare parts as each phase is replaced. By migrating
in phases, the blows to the budget are lessened.
5. Make a wish list
Begin developing a list of priority issues that

you would change, if you could. Be sure to include
operations and maintenance as well. Include specific problems if you know them, such as specific
loops running in manual, field shorts or recurring
instrument problems, lack of backup power, safety
concerns, or process improvements.
An example is to add wireless systems in
the plant so operators could stand at a specific
piece of equipment and control it using a handheld operator screen or even a tablet. Be creative. Technology is changing and there are many
options available to increase productivity and
make system maintenance easier. Dont forget
about the control room furniture. If you upgrade
to a modern control system, why not spend a little money on the control room to make the operators jobs easier?
6. Develop a functional specification

for a migration plan
There are many request for proposals and

specs for upgrades that are less than sufficient
to quote a job accurately. It doesnt mean that a
qualified integrator cannot quote the project, but
the more unknowns and assumptions that a vendor has to take on, the more contingencies they
Plant and operations managers need to be aware that their distributed control systems (DCSs) and programmable logic controllers (PLCs) could be obsolete and they should take appropriate steps to deal with
the problem. Courtesy: Cross Company
P2
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
My operators have poor visibility to

potential issues.
They need to view, process, and make
informed decisions - clearly and quickly.
YOU CAN DO THAT

Improve operations performance. Operator performance can impact plant
safety and process availability. Emerson sets your operators up for success by using best-of-class
technology, proven processes, and an understanding of human limitations and strengths. The DeltaV
distributed control system can help reduce operator stress, limit human error, and provide intuitive
data to run your plant more efficiently. Better visibility better performance. Learn more at
www.emerson.com/operationsperformance/

The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2017 Emerson Electric Co.

have to put in the quote. It then becomes
a matter of who guesses best, is willing to
take on the most risk, or play the changeorder game. Regardless of the method,
the corporate budget is also at greater risk
with a higher number of contingencies.
A well-done functional specification
will allow the company to plan the best
method with the requirements that are
important to your company and specific to

the system. The key is that the results are
clearly defined and contingency is minimized. As long as the functional specification is followed, the end result will be how
you desired it and not how an integrator
interpreted the vague RFQ.
A good functional specification will
also provide the company with an accurate
Be creative. Technology is
changing and there are
many options available
to increase productivity
and make system
maintenance easier.
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budget and sample schedule so everyone

can plan and budget for the migration
properly.
This preparation and planning for
system migration does not have to be
outsourced if the capability is there
inhouse. If the project needs to be outsourced, find an integrator that has
experience in performing these types
of migrations and the preparation that
goes along with it.
The functional design specification is
a very important and critical part of this
entire process. There are many variations
and interpretations on this type of document. Its crucial that the selected vendor
understands what is needed. Just remember: there is a difference in the quality of
the end results.
Effective implementation of these
steps will provide the company with
spares, backups, and the proper licensing
to ensure you are prepared for dealing
with the existing system. The drawings
and wish list will help to prepare for
developing a good functional specification, which is the execution process
to ensure that you know your end goals
and have engineered the roadmap to get
there.
These steps prove a little planning
can go a long way to help the company
properly plan for dealing with obsolescence when it occurs. ce
Jeff Morton is a sales manager at Cross
Company Integrated Systems Group.
Cross Company Integrated Systems
Group is a CFE Media content partner
and a CSIA member as of Nov. 23, 2016.
Edited by Jack Smith, content
manager, CFE Media, Control Engineering, jsmith@cfemedia.com.
P4
JANUARY 2017
CONTROL ENGINEERING
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INSIDE PROCESS steam condensate piping
How to set up proper

steam condensate piping
Steam condensate systems must have proper piping to ensure optimal performance.
ll steam condensate systems for

commercial, industrial, and any
other applications need to have
proper piping (see Figure 1).
When a steam-to-water heater
with a modulating control valve is used, the
condensate from the float and thermostatic
trap should not be lifted (see Figure 2), or else
the system wont be able to control the temperature. Thats because the pressure in the coil
will be too low to push the condensate up to an
overhead return.
When this happens, the heat from the condensate will transfer through the coil into
the hot water, even though the controls have
sensed the water is at or above its setpoint.
When there is an overhead condensate return,
provisions should be made for gravity to drain
the condensate to a lower receiver and pump
the condensate to the overhead return.
Heater operation
A heater is expected to operate with 15

PSIG at the inlet of the control valve. There is
a 10-ft lift from the trap outlet to the overhead

return. The 10-ft column of water exerts a back
pressure on the trap outlet of 4.5 PSIG.
A typical pressure drop across a temperature control valve is 30% (about 4.5 PSIG) when
fully open, so 10.5 PSIG is left to enter the coil.
As the steam condenses in the coil, the pressure
will continue to drop. When it drops below the
back pressure, the heater will stall. The sensor
then will see a drop in temperature and begin
to open the steam valve, so both steam and condensate can begin to flow again.
When a steam-to-water heater with a modulating

control valve is used, the condensate from the
float and thermostatic trap should not be lifted,
or else the system wont be able to control the
temperature.
MORE
ADVICE
KEY CONCEPTS
Steam condensate systems for
commercial and industrial applications
must have proper piping.
A typical pressure drop across a
temperature control valve is 30%
when fully open.
When the pressure drops below
the back pressure, the heater will
stall; the sensor then will see a drop
in temperature and begin to open the
steam valve, so steam and condensate
can begin to flow again.
Figure 1: All steam condensate systems for commercial,

industrial, and any other application need to have proper
piping. All images courtesy:
Cummins-Wagner
GO ONLINE
Link to additional online resources,
steam system best practices, and
related content at
www.controleng.com/archives,
under January 2017.
CONSIDER THIS
When was the last time your plant
conducted a steam trap audit?
www.controleng.com
CONTROL ENGINEERING
JANUARY 2017
| P7
INSIDE PROCESS steam condensate piping
When the sensor sees a

drop in temperature, it opens
the steam valve, so steam
and condensate can begin
flowing again.
This process causes the water temperature

to increase and the valve to close. The high
temperature (HT) condensate will stop flowing, and the heat from the HT condensate will
transfer to the domestic water side. This causes
an uncontrolled temperature rise, possibly to
unsafe levels. ce
Figure 2: When a steam-to-water heater with a modulating control

valve is used, the condensate from the float and thermostatic trap
should not be lifted.
Richard Goins his the manager of engineered

services at Cummins-Wagner Co. Inc. Edited by
Jack Smith, content manager, CFE Media,
Control Engineering, jsmith@cfemedia.com.
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well-recognized name in the industrial automation market,

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ecently announced hardware

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he need for energy efficiency

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or decades our industry has

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A common question I hear from
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Focusing on reliability as a business
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technology and engineering-based

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Reliability is the quickest, most proven
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Focusing on reliability as a business

strategy, can improve safety,
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Our research and experience show
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Companies achieve 15 days more
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while youd think they spend more
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Jim Nyquist
Group President,
Emerson
Automation
Solutions
The demand for increased asset

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Emerson Automation Solutions, Austin, Texas
infocentral@emerson.com
+1 800 833 8314
www.emerson.com
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n todays engineering world

the value of teamwork and
partnerships shouldnt be underestimated. Both merit an integral
role within your comprehensive
business strategy, particularly for
companies contemplating a Smart
Factory environment. Within the
engineering department, recent
innovations have removed
long-standing barriers to
inter-disciplinary collaboration.
EPLAN USA corporate office in Schaumburg, IL
The traditional sequential method

of product development, where
engineering disciplines work in their
own insulated silos, tossing projects
back and forth between silos, is yielding to more productive approaches.
With the latest CAE and CAM
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The turn-around of projects becomes
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As the Smart Factory develops, the

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it provides.
The tools to facilitate greater teamwork and collaboration are here
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the EPLAN Platform that
enables them to connect to
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with enterprise systems.
Users can share basic data,
work collaboratively, smarter
and faster.
The next threshold is mechatronic:
EPLAN, in conjunction with sister
company CIDEON, has launched
Syngineer, a cloud-based platform
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control systems engineers to combine
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external partnerships to allow
engineering collaboration in other
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inter-departmental management of
projects and resources.
EPLAN and Rockwell Automation
have partnered to develop
bi-directional interfacing between
EPLAN and Studio 5000, Studio 5000
Architect and IAB, to synchronize
and accelerate software and hardware
design. EPLAN joined forces with big
Bruce Rodewald
President & CEO
EPLAN Americas
Nows the time

to stop thinking
of engineering as
the work of one,
but rather as the
power of many.
data PLM companies to create
integration solutions for EPLAN and
products like Siemens Teamcenter and
SAP Engineering Control Center.
The digitalization of industry offers
significant benefits for companies
embracing horizontal and vertical
integration teamwork and
partnership approaches internally
and with suppliers and customers.
Nows the time to stop thinking of
engineering as the work of one, but
rather as the power of many.
info@eplanusa.com
www.eplanusa.com
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ith a new President in the

Oval office, the manufacturing
industry, which has been hit hard
by bad government policies in the
past decade, is justifiably asking
What is the future of American
manufacturing? Will our plants, and
with them our jobs, continue to move
to Mexico and China or shall we start
bringing them back?
The Kumar family has played a
significant role in this election cycle,
supporting Trump. Shalabh Kumar,
the Chairman and founder of the
AVG Group of Companies, met
with Mr. Trump early on in the
campaign, and was impressed that
he is a businessman and not a
politician. He subsequently ran
Trumps Indian American campaign
that spread like wild fire and helped
him win the Presidency.
AVG started in 1976 with nothing

but an innovative concept, the
Programmable Limit Switch
PLS, that changed American
manufacturing forever. Trump will
create the environment that will
encourage companies like AVG to
grow and prosper.
Trump will reduce corporate taxes
from 35% to 15% and remove
regulations that kill American
manufacturing. We saw an early
example of that this past December
when Mr. Trump persuaded the
Carrier plant to keep 1100 factory
jobs in Indiana, instead of moving
them to Mexico.
Under Trumps leadership, we
can be sure that the Trans-Pacific
Partnership Deal is dead and currency
manipulation by China is eliminated.
Vikram
Kumar
President,
EZAutomation
EZAutomation control products

proudly carry the Made in
America stamp unlike their
competitors. We thank all those
who continue to support
American Made products and
look forward to a better America.
The EZTouch HMI and other EZAutomation control

products proudly carry the Made in America stamp
Trump has set a goal to Make
America Great Again, and he has
exactly the skills and attitude we need
in the White House to lead resurgence
of American manufacturing.
AVG, among other things, designs,
manufactures and sells industrial
automation products, but unlike our
competitors, AVG products are made
in America, and also exported to
countries like China, Mexico
and India!
Industries such as PCB and

Contract Manufacturing, and the
Press Industry will come back to
the USA. Finally, 35,000 customers
of AVGs EZAutomation division,
primarily small U.S machine builders, can stop worrying about cheap
Chinese imports and instead focus
on what they do best: Innovate.
I am truly excited for the future
of American manufacturing.
The EZTouch HMI and other
EZAutomations EZTouch HMI
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oore Industries, a world leader

in the design and manufacture
of rail, panel and field instruments
for industrial process control and
monitoring, system integration
and factory automation, continues
its investment in developing
Functional Safety technology to
address the expanding need for high
reliability IEC 61508 compliant
instrumentation for Functional
Process Safety applications.
FS Functional Safety Series instrumentation
Safety practitioners look to a new

generation of equipment specifically
designed and approved for use in
Safety Instrumented Systems (SIS)
utilizing Electrical/Electronic/
Programmable (E/E/PE) technologies.
At Moore Industries, we are
dedicated to developing reliable
instrumentation that meets the
needs of safety practitioners striving
to keep their people, processes,
plants and communities safe. Since
2006 Moore Industries has released
products in the Functional Safety
series including:
STA Functional Safety Trip Alarm,
designed to function as a safety
logic solver approved for single use
in Safety Instrumented Systems
(SIS) up to SIL 2 and in redundant
architectures (1oo2, 2oo3, etc.) up
to SIL 3.
Growth in Functional Safety

technology is driven by an increased
awareness of property destruction,
injuries, and fatalities associated with
tragic accidents occurring in process
plants. Companies are increasingly
aware of obligations to mitigate risks
posed by hazardous operations
including the rising cost of litigation,
making safety the focus of risk
management executives worldwide.
SRM Functional Safety Relay

Module, SIL 2 capable relay
repeater model that accepts a single
contact closure input from a logic
solver trip output such as the
Moore Industries STA Safety Trip
Alarm or the SPA2 Programmable
Limit Alarm Trip.
Organizational management
recognizes risk reduction and the
economic rewards of utilizing a
properly designed process systems
optimizing reliability and safety.
Companies are actively taking steps to
comply with various recognized safety
standards such as ANSI/ISA 84 and
IEC 61508/61511.
SSX and SST Functional Safety

Isolators and Splitter, designed to
protect and enhance loops and
also pass valuable HART data,
certified for use in an SIS up to SIL
3 in monitor mode, where only
the input circuit is part of the
safety function, or SIL 2 in single
use mode.
Scott
Saunders
Chief Executive
Officer, Moore
IndustriesInternational, Inc.
We are dedicated to developing

reliable instrumentation that
meets the needs of safety
practitioners striving to
keep their people, processes,
plants and communities safe.
STZ Functional Safety Dual
Input Smart HART Temperature
Transmitters, designed to accept a
single or dual input from a wide
array of sensors and analog devices,
and Certified by exida to IEC 61508
for systematic integrity up to SIL 3
and for random integrity up to SIL 2.
Moore Industries continues to develop
Functional Safety instrumentation
providing high quality and reliable
solutions for the ever-expanding needs
of our customers. Watch for new
Functional Safety products in the
upcoming months on our website at
http://www.miinet.com/
info@miinet.com 800-999-2900
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s a world leader in drive

technology and a pioneer in
drive-based automation,
SEW-EURODRIVE has established
a reputation for quickly solving the
most difficult power transmission
and motion control challenges.
We introduced the gearmotor in
1931 and in the 86 years since
then, we have been bringing the
best in drive technology to our
customers worldwide.
U.S. Corporate Headquarters in

Lyman, South Carolina
Quickly solving problems so that our

customers can be more productive
and profitable continues to be our
priority. We offer the broadest
product line in the industry from
gearmotors and heavy industrial
gear units to electronic drives,
software and complete drive-based
automation systems.
Our products are based on a unique

system of modular components that
can be assembled in literally millions
of different configurations so every
drive solution is custom built to our
customers exact specifications.
Our regional assembly centers stock
millions of dollars of our modular
inventory for quick delivery of drive
solutions and spare parts anywhere in
the U.S.
At SEW-EURODRIVE our
expertise doesnt stop with
the sale of our products.
We offer one of the most
accessible customer support
systems in the industry.
Our trained product
specialists are readily
available for on-site
start up assistance and
applications support.
In addition, our PT Pilot
selection tool quickly selects the
drive for your specific needs.
Our customer service personnel,
engineers, product specialists,
and service technicians are
available to answer questions
and troubleshoot problems.
SEW-EURODRIVE offers on-call
emergency technical support
around the clock.
MOVIGEAR
Mechatronic
Drive System
The MOVIGEAR
Mechatronic Drive
System for horizontal
materials handling from
SEW-EURODRIVE sets new
standards in terms of efficiency
and functionality.
reduces total start-up cost

and annual operating costs
in your material handling
system by 20-30%!
MOVIGEAR not only combines the
gear unit, motor and drive electronics
within one highly reliable, efficient,
and hygienically designed unit, it also
reduces total start-up cost and annual
operating costs in your material
handling system by 20-30%!
MOVIGEAR also eliminates excess
inventory since it allows the use of a
single ratio to replace several
different ratios.
We offer the broadest product line in the industry

from gearmotors and heavy industrial gear units
to electronic drives, software and
complete drive-based automation systems.
864-439-7537 www.seweurodrive.com
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nitronics is a global company

with over 25 years of expertise
designing and manufacturing PLCs
with integrated HMI; we introduced
the very first all-in-one PLC on
the market and have continued
to innovate ever since. Today
Unitronics offers several lines of allin-one PLC+HMI solutions, ranging
from a microcontroller with two-line
text display to a powerful PLC with
15-inch HMI that can support for up
to 2000 I/O points.
customers at every step of the way

with all-in-one software, expert
technical support and dedicated,
helpful staff.
All of Unitronics controllers are

programmed using single-environment
programming software. In one
environment, the user can program
the ladder logic, design HMI screens
and configure communications. This
all-in-one software is intuitive and
easy to learn, enabling users to reduce
programming time by as
much as 50%. We also
include advanced software
utilities for remote access
and data logging.
Unitronics offers our
software to all users at
no cost; the full version
can be downloaded
from our website at
http://unitronicsplc.com/
software-visilogic/
Unitronics international headquarters in Tel Aviv, Israel
This all-in-one control solution helps
engineers and machine builders do
their jobs better; integrated units
save space and reduce the amount
of wiring necessary, as well as
eliminating the need for PLC-panel
communications. Unitronics also
applies the all-in-one philosophy
to every aspect of our business.
It takes more than just buying a unit
to complete a project and we are
committed to supporting our
Of course, even with a robust

PLC and intuitive software, many
projects still run up against obstacles.
Unitronics superb support team is
more than capable of handling any
problems that might occur; our
application engineers are available
at every step of your project to
offer guidance and troubleshooting.
Unitronics never charges for technical
support because we stand behind the
quality of our products completely.
From the headquarters in Israel,

Unitronics has grown to include a
US subsidiary office and a trusted
network of almost 150 distributors
in over 50 countries.
This growth has been possible
because Unitronics is committed to
not just manufacturing excellent
products but also to providing
excellent customer service. As a
company, we strive to be as easy to
work with as our PLCs are. Unitronics
customers can feel confident that they
are getting not only an all-in-one PLC
but the complete package they need to
make their application successful.
For more information, visit us online
at www.Unitronics.com or contact us
directly via phone, 617-657-6596, or
email, USA.Sales@Unitronics.com.
We are committed
to supporting our
customers at every
step of the way with
all-in-one software,
expert technical
support and dedicated,
helpful staff.
617-657-6596 USA.Sales@Unitronics.com www.Unitronics.com
n August 2016, Beijer

Electronics made its
largest product announcement in its 35 year history.
The X2 series is its next
generation HMI product
offering comprised of six
product families and
dozens of configuration
options. The X2 series
combine a common design
with strong performance to
power todays modern
HMI solutions.
Headquarters for the Americas

in Salt Lake City, Utah
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All Beijer Electronics models

and configurations
include iX runtime software
X2 base - Cost-effective, UL approved HMIs; available in

5, 7, 10 inch display sizes.
X2 pro - High performance, UL and marine approved HMIs for
most automation needs; available in 4, 7, 10, 12, 15, 21 inches.
X2 marine - Built for life at sea with hi-bright display, optional
IEC 61131-3 PLC support; DNV, GL, LR, ABS, KR and CCS
approvals; available in 7 and 15 inches.
X2 control - Integrated IEC 61131-3 CODESYS control with dual
and quad core CPUs; available in 4, 7, 10, 12, 15 inches.
X2 motion - Integrated IEC 61131-3 CODESYS motion + CNC control with dual
and quad core CPUs; available in 4, 7, 10, 12, 15 inches.
X2 extreme - Rugged HMIs for tough environments including hazardous locations (Class I
Division 2, ATEX zones 2 & 22, IP 66, NEMA-4X, UL 50E Type 4X outdoor), extreme
temperatures (30 to +70 C), high vibration and high shock; optional IEC 61131-3 CODESYS,
hi-bright displays, fully-sealed models with M12 connectors; available
in 7, 12, and 15 inches.
With over 50 models and configurations, all include Beijer Electronics
iX runtime software. Each operator panel is programmed by Beijer
Electronics separately licensed iX Developer software. Configurations
can be coupled with Beijer Electronics WARP Engineering Studio and
its remote IO modules (network, analog in/out, digital in/out.)
Phone: 1.801.466.8770
www.beijerelectronics.com
www.beijerinc.com
12/22/2016 12:53:07 PM
ADVERTISEMENT
ce201701_execV_BEIJERhalf.indd 1
LOGO
ounded in 1984, Dataforth is a recognized global

leader in the design and manufacture of signal
conditioning modules and industrial data acquisition &
control systems.
Our mission is to
set the highest
standards of
product quality,
performance, and
customer service,
Corporate Headquarters, Tucson, Arizona
says Robert Smith,
VP of Sales and Marketing. We know that signal
integrity is critical and so our products are all
designed to ensure the most reliable, cost-effective
isolation and protection for customers measurement
and control signals and connected equipment.
Unparalleled Data Acquisition & Control
MAQ20: Dataforths 3rd generation DAQ system,

based on 30+ years of experience in the industrial test
and measurement and control industry, offers the
industrys lowest cost per channel, 1500Vrms channelto-bus isolation, 0.035% system accuracy, and two
dedicated software packages with integral PID control.
Two new modules have just been added to the system

and two more are on the way. The MAQ20 is ideal for
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environmental monitoring applications.
8B isoLynx SLX300: Builds on proven reliability of
the SLX200 and miniature 8B signal conditioners.
SCM5B isoLynx SLX200: Implements industry
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MAQ20 DAQ System

with 5B, 7B, and
8B Signal Conditioners
Unrivaled Signal Conditioning
Our signal conditioner families ensure outstanding accuracy, isolation, and

protection, Smith states, adding that custom modules are available upon request.
Modules provide1500Vrms transformer isolation, up to 240Vrms field-side protection,
0.03% to 0.05% accuracy, and wide operating temperature range.
SCM5B Analog Modules Ideal for temperature, pressure, flow

SCM7B Process Control Modules A compact, low-cost solution
SensorLex 8B Analog Modules Miniature size for embedded & portable apps
DSCA DIN Modules DIN rail mount for
temperature, pressure, flow
All 1200+ Dataforth products are manufactured in Tucson, AZ.

The Quality Management System is ISO9001:2008 registered.
sales@dataforth.com
800-444-7644 dataforth.com
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or more than 30 years,

Maple Systems, Inc., has
supplied innovative control
solutions for the automation and
industrial controls marketplace,
and specializes in the design,
manufacture, and support of:
the industry, our solutions

streamline your process, offering
top quality and reliability. In
addition, Maple Systems provides
complimentary technical support,
and several Class I, Division 2
certified models.
Touchscreen HMIs
HMI + PLCs
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HMI Solutions for Every Machine

Maple Systems control
products are utilized worldwide
in industrial, OEM, automation,
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Packaging, oil and gas, medical,
food and beverageNo matter
Maple Systems Inc., Everett, Washington
PLC Integration
Maple Systems products integrate
with more than 100 brands of
programmable controllers from
the biggest names in PLCs

including Allen Bradley, Schneider
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Best-Value Products
As a premier provider of industrial
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Maple Systems truly is your
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Larry St. Peter

CEO Maple Systems
What can we help

you control?
Learn more today:
www.maplesystems.com
info@maplesystems.com
www.maplesystems.com
Phone: 425.745.3229
For more than 30 years our focus has been supplying innovative control solutions.
ce201701_execV_MAPLEhalf.indd 1
12/22/2016 1:19:29 PM
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Wednesday, October 22, 2015

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CONTROL ENGINEERING
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DIGITAL EDITION EXCLUSIVES
DE1 Incorporating cybersecurity

awareness into OT
Using cyber-situational awareness platforms to enhance control system personnel needs to be part of a greater design goal and should act as an invisible
layer for an operations technology (OT) environment. Here are four tips for
cybersecurity awareness, and six responses to zero-day threats.
DE3 Robotics software for the next generation
Courtesy: Anil Gosine, MG Strategy+
Educators, researchers, and robotics companies have collaborated to develop software that enables robots to
work in new applications to help shrink the industrial manufacturing skills gap. As a result, more intelligent
robotics software now is enabling greater robotics capabilities for the next generation of technology and manufacturing workers.
ONLINE EXTRAS
(Click on the headlines or search www.controleng.com.)
IT, OT teams need to keep manufacturing systems running

Security professionals on the information technology (IT) and the operations technology (OT) sides
of the house have to truly understand the main goal, which is keeping the manufacturers systems up
and running at all times.
Neural network learns to recognize sounds

MITs Computer Science and Artificial Intelligence Laboratory (CSAIL) researchers have developed
techniques to improve sound recognition for computers, which could enhance machine learning.
How to develop a speech into a must-attend event

Understanding the audience is vital to a successful speech and growing your reputation within the industry.
Four ways to better manage small capital projects

Focus on collaboration, risk assessment, communication and review to meet time, budget goals.
The crux of manufacturing

For todays manufacturing plants, a key solution may be advanced computerized maintenance management
systems (CMMS).
Three tips to train a multigenerational workforce

Managing a generationally-diverse maintenance staff can be challenging at times, but the wide range of skills
and experiences gained from a multigenerational workforce can drive high productivity once reigned in.
www.controleng.com
CONTROL ENGINEERING
JANUARY 2017
| 67
DIGITAL EDITION exclusive
Incorporating cybersecurity
awareness into OT
Using cyber-situational awareness platforms to enhance control system personnel needs to be
part of a greater design goal and should act as an invisible layer for an operations technology (OT)
environment. Here are four tips for cybersecurity awareness, and six responses to
zero-day threats.
ndustrial control system (ICS) security is

no longer merely about preventing hackers or having a strong physical perimeter.
There is an underground digital economy
that now offers multi-billion dollar incentives for potential corporate rivals or adversaries
to exploit ICS vulnerabilities. And the influx of
information technology (IT) into the OT further
highlights the need for security by design rather
than by association.
So its imperative that control system personnel be aware of design goals even more than
developing software platforms. Users also need
to have a greater situational awareness, particularly when it comes to control systems that are
tied to critical infrastructure.
Aggregating digital data on an industrial
network with situational awareness solutions
allows for efficient correlation and analysis of
information, which makes sharing information
a lot easier.
Cybersecurity awareness: Four tips
MORE
ADVICE
KEY CONCEPTS
Users also need to have a greater
situational awareness, particularly
when it comes to control systems that
are tied to critical infrastructure.
Cyber attackers are developing
exploits for zero-day vulnerabilities
that have not been disclosed
Investing in data collection,
management, and analysis is needed
to understand how the systems are
operating.
GO ONLINE
See additional articles from the
author online at www.controleng.com.
CONSIDER THIS
What other steps can be taken to
safeguard critical infrastructure?
DE1
JANUARY 2017
Cybersecurity awareness tips include:
Proper awareness of a facilitys cyber

network
In-depth understanding of the facilitys
cybersecurity operations
Appropriate and ongoing assessments of
the existing operations within the network
to identify potential vulnerabilities
Continuous monitoring of unusual activity on the cyber network coupled with
the ability to mitigate threats before they
occur.
Data should be aggregated from multiple control systems, controllers, smart field devices, and
network switches to enable efficient information
correlation and analysis. Continuous monitoring and collecting real-time data will help detect
CONTROL ENGINEERING
unfamiliar activity. This provides owners and

cybersecurity auditors unprecedented detection
capabilities and visibility.
Applying cybersecurity
Cybersecurity implementations should incorporate active machine learning and modeling

that continuously learn the operational system,
adapt to changes within it and detect operational and cyber threats in real-time. The machine
learning process enhances the capability of a
platform to provide early detection of incidents
and enriches advanced detection algorithms for
fast incident identification and alerting. This
process minimizes human error and reduces
downtime.
Enhancing operator security awareness
applies to a variety of industries, including the
industrial sector, aircraft manufacturers, automotive, and manufacturing. Control systems
can produce a huge amount of data, based on
their connected components and environments.
Cyber-situational awareness provides a tool for
users to better understand their environment,
so they can make better decisions about defending themselves. Situational awareness solutions
need to address three things to transform the
data into awareness: perception, comprehension
and prediction.
Control system solutions should allow users
to run real-time incident analysis and provide
complete visibility and control during the inventory and audit process. Integration with existing control systems should be seamless without
impact on operations.
Many cybersecurity efforts focus on protecting assets against known threats that have been
made public. However, attackers are developing
exploits for vulnerabilities that have not been
disclosed, also known as zero-day exploits.
Users must have an understanding of the interactions among vulnerabilities, events, and
www.controleng.com
baseline systems to be able to militate against

these threats. It also can help them forecast
potential security gaps and detect operational
irregularities or breaches.
Six responses to zero-day threats
If a vulnerability remains unknown, the software affected cannot be patched, and anti-virus
products cannot detect the attack through signature-based scanning. The typical zero-day attack
lasts an average of eight months, which gives
attackers lots of time to steal information and
leave without being detected.
Companies can help secure themselves by:
Employing good preventive security
practices
Having real-time protection that deploys
intrusion-prevention systems
Having a detailed understanding of their
environment
Planning incident response measures with
defined roles and procedures
Limiting the connections and privileges to
those required for business needs
Fostering collaboration in the security
industry.
Executives should assume their firms have

been compromised and that it will occur again
if they do not have sufficient measures in place.
Prevention can be limited, so they should invest
in breach detection so that they can act on the
compromises based on the processes in place.
At the end of each week, there are spikes in
malware distribution because attackers know
www.controleng.com
that employees take their laptops home and

connect their machines to Internet networks
that arent secure. As a result, cloud-based security firms are seeing increased security alerts
popping up on Mondays. Executives should
understand the legal implications of cybersecurity risks, establish an enterprisewide risk
management framework and have access to
independent cybersecurity consultants that regularly participate on board or C-level meetings.
Awareness is critical
With the growing dependency on digital

devices and technology within critical infrastructure, owners and customers need to understand the environment in which they operate,
and accurately predict and respond to potential problems; with the ability to anticipate what
can occur on these systems, management can
develop effective countermeasures to protect
critical facilities.
Significant investment in data collection,
management, and analysis is needed to continuously gain visibility of how the systems are
operating. Having situational awareness of the
OT environment and responding to the threat
detected, security can be greatly improved
from just relying on building a perimeter that
is expected to endure attacks. Any change in
security must be able to demonstrate security
value to the business and comply with regulatory requirements. ce
Its imperative that

control system personnel be aware of design
goals even more than
developing software
platforms as well as
have a greater situational awareness for control
systems that are tied
to critical infrastructure.
Courtesy: Anil Gosine,
MG Strategy+
Anil Gosine is global program manager at MG

Strategy+. Edited by Chris Vavra, production editor, Control Engineering, CFE Media,
cvavra@cfemedia.com.
CONTROL ENGINEERING
JANUARY 2017
| DE2
Robotics software
for the next generation
Educators, researchers, and robotics companies have collaborated to develop software that
enables robots to work in new applications to help shrink the industrial manufacturing skills gap.
As a result, more intelligent robotics software now is enabling greater robotics capabilities for
the next generation of technology and manufacturing workers.
MORE
ADVICE
KEY CONCEPTS
Students are getting plenty of
hands-on training and instruction
from universities and using the latest
developments to give them an edge
as they graduate.
Universities are using open-source
robot software to help students learn
and gain additional knowledge from
other companies.
GO ONLINE
Read this story online for additional
information about the latest robotics
development as well as a video about
ROS-I at www.controleng.com.
CONSIDER THIS
What other developments do you
see happening in robotics regarding
software development?
he days of robots as dim-witted devices are gone. The future is filled with
smart sensors, software and end-ofarm tooling (EOAT). Its the brain
behind the brawn. The puppeteer
pulling the strings. The escape from relentless
monotony. Without software, however, brilliant
hardware goes nowhere.
Software cant do it alone. Those robot
brains extend human capabilities and are a
reflection of our vision for whats possible. That
vision gets keener with every generation and
every technological leap. Sophisticated software
and intelligent robotics depend on the evolution
of those doing the research, design, specification,
and implementation.
At the Tri-Rivers Career Center in Marion,
Ohio, home of the Robotic Advanced Manufacturing Technical Education Collaborative (RAMTEC), students of all ages are preparing for a
future populated with intelligent machines and
connected systems.
Its important that kids start understanding the concept of robotics, said Ritch Ramey,
RAMTEC engineering coordinator. Were going

to see it expand probably tenfold in the use of
robots over the next 15 to 20 years. They should
at least know the basics of robotics.
According to the International Federation
of Robotics (IFR), global robot deployment will
more than double from 1 million robots in 2009
to 2.3 million by 2018. To keep those robots
humming and evolving, a skilled workforce
will be needed. This is a tall order that requires
closing the skills gap in automation and bringing younger workers into the fold. RAMTEC is
answering the call.
Software certification for robots
Learning to program robots, and the ins and

outs of various software platforms, is an integral
part of the curriculum at RAMTEC. Students learn
to use robots, as well as robotic welding, programmable logic controllers (PLCs), hydraulics, pneumatics, computer-numerical controls (CNCs),
computer-aided design (CAD), and 3D printing.
These are the necessary building blocks for any
budding engineer or robotics technician.
Ramey, a credentialed instructor at RAMTEC, said the collaborative plans to add machine
vision to their robotics curriculum, as vision-guided robotics has become essential to many industrial applications. With Industrie 4.0 coming and
the Industrial Internet of Things (IIoT) vital to the
smart factory concept, he says RAMTECs students
also will need to learn the Cisco platform as they
enter an ever-connected industrial world.
RAMTEC instructors have credentials to teach
on several industrial robotics platforms and Ramey
Figure 1: High school students prepare for industrial certification by learning how to use robot
programming software both in the virtual world
and hands-on with an industrial robot. Courtesy: TriRivers Career Center (RAMTEC), Robotic Industries
Association (RIA)
DE3
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
hopes to soon add more types of collaborative

robots to the program.
Our students have to do exactly what the
industry people do, Ramey said. The same
amount of time, same assignments, same e-learning, and same tests to get their credentialing.
Robot programming wish list
Ramey said he hopes to see the robot teach

pendants get smaller like a PlayStation controller, and much easier to use. Down the road, I
see them going to even your basic cell phone and
tablet to program robots.
He also would like a feature that he saw at
IMTS 2016 in Chicago to become widespread.
Where you can just drag the end effector or
end of the robot around and put your position
points where you want them, and then it will
remember those, instead of using XYZ coordinates and all the jogging coordinates, he said.
That will make things so much simpler. You
actually can go in and grab the robot, show it
what you want it to do and then tweak the program. That needs to become universal in all
robots. A must is being able to plug the teach
pendant right into the robot, he added, versus
using a flash drive to transfer a program to the
robot.
I think the next generation of software will
be able to reach a younger generation of students. I think all of the industry is looking at
how to get more high school and junior high
students involved. Schools also are pushing
robotics down to the elementary level. The next
wave of students will be more robot savvy than
this generation, because years of experience
www.controleng.com
and terminology will help them learn faster.

Industry might have to catch up with the kids at
that point.
Robotics university
Along the banks of the Hudson River, students also are readying themselves for a future
in advanced manufacturing. Glenn Saunders
is helping prepare the next generation of engineers and roboticists for the age of the intelligent
factory.
Saunders is the senior research engineer in the
Center for Automation Technologies and Systems
(CATS) at Rensselaer Polytechnic Institute (RPI)
in Troy, New York. He conducts applied research
with an industry focus in robotics, automation,
and manufacturing. The research work Saunders
and his undergraduate and graduate students conduct often is motivated by a company with a specific need and usually falls into two areas.
We like to say that we do research in robotics, and we do research with robots, Saunders
said. The research in robotics is generally where
were developing robots or were developing very
research-like applications with industrial robots.
Whereas in research with robots, we dont mess
with the native controller, and we use all the tools
that are available to the industrial customer. Thats
really looking at a specific application for a robot, as
opposed to trying to do new and interesting things
with a robot.
Figure 2: Students use

a teach pendant to program a robot to simulate
a palletizing process.
Courtesy: Tri-Rivers
Career Center (RAMTEC),
Robotic Industries Association (RIA)
Years of
experience and
terminology will
help students
learn faster;
industry might
have to catch
up with the kids
at that point.
Open-source software
On the more researchy side, as Saunders referred to it, a lot of what RPI does is in
robot operating software (ROS), which is an
CONTROL ENGINEERING
JANUARY 2017
| DE4
ROS includes software

for mobile bases, which
is beyond most of the
industrial robots.
Figure 3: Advanced programming is used to manipulate a dual-arm industrial robot

for research in repairing satellites in space. Courtesy: Rensselaer Polytechnic Institute
(RPI), Robotic Industries Association (RIA)
Figure 4: PC-based
simulation and offline
programming software
provides a 3-D virtual
development platform
for industrial robot cells.
Courtesy: ABB Robotics,
Robotic Industries Association (RIA)
DE5
JANUARY 2017
open-source robot operating system that

recently celebrated its eight-year anniversary.
We use ROS and we contribute to the opensource community within ROS, Saunders
said. The learning curve is quite steep. There
are powerful capabilities, but its certainly not
easy to use. Young people who are comfortable
around a computer and the Linux operating system pick it up more easily.
ROS has a lot of different software capabilities and one of them is visualization, he added.
It includes software that does things like path
planning. The software will come up with a way
to move the arm from point A to point B without crashing into things in the work envelope. It
also includes software for mobile bases, which is
beyond most of the industrial robots.
CONTROL ENGINEERING
Rethinks Baxter robot comes in an industrial

version and a research version. Saunders said the
difference is entirely in the software. The Baxter Research Robot basically gives you access to
a lot of the lower level functions that you would
not normally have access to as an industrial customer, he said.
RPI researchers accessed those ROS-based
lower level functions to develop a mobile inhome assistance robot. Most of the universitys
applications for ROS open-source software have
been on the purely research side. Rensselaer is
looking to the future with membership in the
ROS-Industrial Consortium, which extends the
advanced capabilities of ROS to manufacturing
automation and robotics.
We operate in the industrial space. Thats
why it was important for us to be members of the
ROS-I Consortium, Saunders said. Were full
members and have been for three years. Part of
our mission is to help industry, and in particular
New York state industry, to be more competitive.
For us to do our jobs, we need to be in a position where we can advise our industrial clients
on whats coming down the road. We see ROS-I
as having a pretty big impact on the capabilities
of industrial robots and therefore the capabilities of our industrial partners. Its really us looking forward.
Keeping the industry connected with the educational community will help bridge the skills gap.
Preparing our current and future workforce for
automation and robotics will span that divide. ce
Tanya M. Anandan is contributing editor for the
Robotic Industries Association (RIA) and Robotics Online (robotics.org). RIA is a not-for-profit trade association dedicated to improving the
regional, national and global competitiveness
of the North American manufacturing and service sectors through robotics and related automation. This article originally appeared on the RIA
website. The RIA is a part of the Association for
Advancing Automation (A3). A3 is a CFE Media
content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media,
www.controleng.com
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NEW PRODUCTS and software
Power supply modules for

medical applications
I/O platform for

improved connectivity in
hazardous areas
Rockwell Automations Allen-Bradley Bulletin 1719 Ex I/O platform is
designed to allow users to access data
from field devices and more easily control process operations in hazardous
areas. It is part of the PlantPAx distributed control system (DCS) from Rockwell Automation. The Bulletin 1719
Ex I/O allows users to monitor operations using a common platform that
communicates with the DCS or other
automation systems. The I/O platform
operates in a wide temperature range
and is designed for use in industries
with hazardous applications, such as oil
and gas, chemical, life sciences, pharmaceutical, and food and beverage. In
addition, an EtherNet/IP device-levelring (DLR) adapter enables DLR topology to help improve network resilience,
and an optional N+1 power supply provides power redundancy. Three chassis
models are available, providing scalability for anywhere from eight to 45
I/O modules on a single adapter.
Rockwell Automation
Traco Powers TMF series of ac/dc

power supply modules are designed
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the design in. The thermal management enables an operation within a wide temperature range of -25 to 70C and the isolation system is designed and approved for an
altitude of 5,000 m. This makes the power supplies suitable not only for stationary
applications but also for transportable medical equipment.
Traco Power,
www.tracopower.com
Touchless angle
sensors for measuring
angular positions
Novotechniks RFC4800 Series
of touchless angle sensors are
designed to measure angular position up to 360, revolution counter
and speedwithout wear. Features
include programmable zero point
offset, measurement averaging and
sign of rotational direction. RFC4800 Series has a resolution of 14-bits across 360,
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the IO-Link communication protocol, which only needs three wires to simultaneously transmit measured values and status information. The status bit can signal a
controller if a sensor needs replacement and the controller can detect the new device
and automatically configure it based on stored values minimizing down time. Sensors
are sealed up to IP69K and it has an operating temperature range from -40 to 125C.
www.rockwellautomation.com
Novotechnik,
www.novotechnik.com
Differential pressure switches and indicators

Clark Solutions Series 604 differential pressure switches and Series 699 differential pressure indicators and transmitters feature a ceramic fulcrum lever technology and are developed for a variety of specialized pressure sensing applications.
The Series 604 differential pressure switches are designed for monitoring filter and
fan pressures and are designed for storage temperatures from -40 to 185F (-40 to
85C). The Series 699 differential pressure indicators and transmitters are designed
for use with air and neutral gases and are available in three configurations and several pressure ranges, offering different levels of function and cost. Series 699 indicators/transmitters are generally used for measuring low differential pressures such
as in airflow measurement, fan static pressures, and specialty room pressure measurements. They are designed to operate in storage temperatures from 14 to 158F
(10 to 70C).
Clark Solutions,
www.clarksol.com
68
JANUARY 2017
CONTROL ENGINEERING
www.controleng.com
See more products daily at www.controleng.com/products.
Industrial PC for
space-restricted
application areas
Panel PC for industrial applications

Advantechs PPC-6151C is a 15-in. true-flat resistive touch
TFT LCD display modular configurable panel PC with a 2.5in. SATA HDD bay. The PPC-6151C can be equipped with or
upgraded to after the fact, various certified mini-ITX motherboards and configured to specific application requirements. In addition to multiple
I/O ports the system features an
integrated PCI/PCIe x 4 slot to
enable flexible expansion. The
entire system is certified with a
front panel IP65 rating for protection from water and dust,
making the PPC-6151C useful
for industrial applications in a
wide range of environments. The
PPC-6151C features a proprietary daughterboard that transmits display panel signals to the
motherboard. This allows customers to select their preferred
mini-ITX motherboard platform and configure the system
specifications and functions according to their usage requirements and budget considerations.
Beckhoff s C6015 Industrial

PC (IPC) is designed for application areas with pronounced
cost or space restraints. Fully
suited to industrial applications,
the multi-core IPC measures just
82 x 82 x 40 mm and includes
the integrated Intel Atom CPU,
which features up to four processor cores. Moreover, the IPC
leverages a robust, aluminum/
die-cast zinc housing, designed
for passive cooling and long-term availability. The device can
work in harsh industrial environments and has an extended
operating temperature range up to 55C and high resistance
to vibration and shock. It can be mounted both vertically and
horizontally on the rear wall of a control cabinet or attached
to a DIN rail. Even in the tightest installation spaces, this permits various mounting scenarios with flexible orientation of
the IPC.
Advantech
Beckhoff Automation,www.beckhoff.com
www.advantech.com
Thermocouple measurement instrument with

military-grade connectors
VTI Instruments RX1032 rugged thermocouple measurement instrument is
designed to provide thermocouple measurement accuracy and acquisition rates and
is configured in a rugged compact form factor that makes this instrument ideal for
use in demanding environments. The RX1032s rugged construction allows the measurement system to be mounted on test pylons, making it ideal for a wide range
of applications, including large scale engine test, health monitoring, HALT/HASS,
rocket motor reliability and wind tunnel tests. It has strong temperature accuracy
(0.12C), data acquisition rates, and a wide operating range from -40 to 70C. Military-grade connectors ensure reliable power and network connectivity, while all
thermocouple and sensor inputs are routed through a protected quick release panel for easy access.
VTI Instruments,
www.vtiinstruments.com
Pneumatic valve and manifold series for tubing installation

AutomationDirects Nitra BVS-3 and BVS-4 series of valves and mainfolds feature
push-to-connect air connections for tubing installation. The BVS-3 series modular
solenoid valves are body ported 3-port (3-way) poppet valves available in 2-position, normally open or normally closed configurations with 12, 24, or 120 V ac coils.
Models are available with an 8 mm Micro DIN connector; most models have removable flying leads, allowing the valves to be used with BVM series manifolds. BVS-3
series valves are also offered in low current models and are available with 3, 5, 12,
or 24 V dc coils. The BVS-4 series modular solenoid valves are two-position, single
spring return, body ported 4-port (4-way) spool valve models. Designed with 1/4-in.
push-to-connect ports and 12 and 24 V dc and 24 or 120 V ac solenoid coils, these
valves have removable flying leads or an 8 mm Micro DIN connector.
AutomationDirect,
www.automationdirect.com
www.controleng.com
CONTROL ENGINEERING
JANUARY 2017
| 69
NEW PRODUCTS and software

See more products daily at www.controleng.com/products.
Remote I/O modules with EtherNet/IP

Moxas ioLogik E1200 line of remote input/output (I/O) modules features support for EtherNet/IP and a
restful API. The ioLogik E1200 is designed as an alternative to expensive and proprietary I/O modules that can
interface with IT systems. The Moxa ioLogik E1200 series is available with a wide range of input and output
types, including voltage, current, digital, pulse, frequency, RTD, thermocouple and more. Existing owners can
gain the additional functionality for free by downloading the new firmware and completing the online registration process. The firmware adds support for both EtherNet/IP and a restful application program interface
specifically designed for IIoT applications that interact with cloud services. The ioLogik E1200 expands Moxas
offering of EtherNet/IP communication products, which including Ethernet switches that can be managed on
a SCADA network and EtherNet/IP gateways that allow communication with Modbus devices.
Moxa Americas Inc.,
www.moxa.com
HMI PLCs for small- and medium-sized machines

Turcks TX500 human-machine interface (HMI) programmable logic controllers (PLCs)
are designed for use in small- to medium-size machines whose processes have to be controlled, displayed and operated locally. Each TX500 is equipped with a Profinet master
and EtherNet/IP scanner, as well as a Modbus TCP and Modbus RTU master. The HMIs
also can be run as field devices for both Modbus protocols. Codesys 3 allows the lean and
simple programming of the PLC and visualization functions. The TFT display with 64,000
colors enables high performance display of graphics and animations. The front panel of the
TX500 series is protected to IP66. It features two RJ45 Ethernet ports, a serial interface for
RS232 or RS485 as well as two USB ports are provided on the terminal side. An additional
SD card slot makes it possible to expand the 128 MB internal data memory.
Turck,
www.turck.com
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| 71
4P
BACK TO BASICS automation principles
Four principles for more

effective automation
Programming is a big portion of process control. Following principles such as customer
collaboration, responding to changes, and emphasizing individuals and interactions can
help a great deal in creating a successful project.
Programming is a big portion of process

control. Consider these four principles for effective and efficient program development: Emphasize individuals and interactions over processes
and tools; Working software over comprehensive
documentation; Customer collaboration over
contract negotiation; and Responding to change
over following a plan. Each principle is crucial
to an effective and efficient program development and can mean the difference between success and failure.
Unanticipated
things happen.
Being adaptable
is as essential as
starting out with
a plan.
MORE
ADVICE
KEY CONCEPTS
An effective and efficient program
development plan can mean the difference between success and failure.
Work process and tools are useful,
but it is the strengths and weaknesses of the individuals and their
interactions with the project that
make the difference.
GO ONLINE
See additional stories from
Maverick Technologies blog,
Real World Engineering, at
www.controleng.com/blogs.
CONSIDER THIS
What other principles also are
effective in improving automation?
72
JANUARY 2017
1. Emphasize individuals and

interactions over processes and tools
While work processes and tools can be useful, they can also be inhibiting. Some tools are
good for generating a skeleton, or perhaps even
a significant portion. Trying to force a tool to
generate the entire program often leads to programming the tool. The same can be said about
forcing a project to follow a work process, as all
projects are not the same. The stages of a work
process should be used as a guide to encourage
the project, not as a measurement to correct.
While work process and tools are useful, it is
the strengths and weaknesses of the individuals
and their interactions with each other, and the
workings of the project that make the difference.
A good team finds the best use of each player.
Those qualities can be enhanced by but not supplanted by work processes and tools.
2. Working software over

comprehensive documentation
This is a step where many stumble. The tendency to continually design to perfection leaves
us always approaching an imaginary object. We
often produce documents that are very detailed
but must be corrected when the finished product
is running. Why? Because you dont know what
you cant see. This is why simulation is essential.
Adding and deleting instrumentation, control
loops and modifying functionality is easier when
you can see it in simulation. When all you can
see is paper and imagination, it is harder for both
automation and operational personal to see and
CONTROL ENGINEERING
understand. This is also the place that easily can

consume the greatest amount of hours designing and redesigning reviews based on what we
see on paper. Getting the project to simulation
(working software) allows all to see its behavior
instead of just imagining it.
3. Customer collaboration over

contract negotiation
Knowing the audience makes a lot of difference between a successful partnership verses two
entities protecting themselves in the divorce. The
commitment to produce a positive result means
both sides have to collaborate to look for winwin opportunities. Trust and commitment are
keys to success. If it becomes a contract negotiation, then it all becomes about the fine print
rather than the larger picture.
4. Responding to change over

following a plan
While the word re-work is often tossed

around as a boogeyman, there has never been a
project that has not required some level of rework. Change is a fact of life. Trying to adhere
to a plan is something that seldom works. Life
is about change. Unanticipated things happen.
Things we thought worked one way turn out to
work differently. Being adaptable is as essential
as starting out with a plan.
It is important to note that these are preferences over tendencies. That doesnt mean you
never plan, document, negotiate, or use work
processes and tools. It means learning to put
things in the best place for the best result. This
doesnt mean there is an absolutely right way
and a wrong way; it means we need to learn how
to balance ourselves to achieve the best results.
Weighing these principles like a set of scales can
help produce a better result. ce
Rocky Chambers, senior control systems specialist, Maverick Technologies, a CFE Media content
partner. Edited by Chris Vavra, production editor, Control Engineering,
www.controleng.com
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