break free from the traditional plc experience - pmmi …€¦ · · 2016-04-21• communication...

2PRODUCT SELECTION HANDBOOK 2016

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Just pay once . . .because once is enough! With traditional suppliers the “upfront” price is not always the price you pay. The costs associated with service contracts, software licenses, access to online resources, etc. can make your PLC purchase a long and painful one.

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ContentsPublisher's Note, by Kurt Belisle

Secrets to selecting and implementing sensors in industrial applications

Exhaustive best practices for specifying PLCs, PACs or PC controllers

Essentials to consider when building out your industrial network

Indispensible product selection tips guaranteeing I/O engineering success

Crucial steps to creating the perfect HMI

Fundamental recommendations for selecting motors and drives

08

09

16

26

30

34

40


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Taking the sting out of just getting started

The beginning of any automation project can be

daunting for a lot of reasons, among them the

sheer volume of variables that you need to address.

And for every variable you encounter, there’s a solution

designed specifically to address that need. Actually, there

are more like a half a dozen solutions for each.

That’s where this handbook comes in. It seeks to

streamline and simplify, in the form of tried and true

advice, things to look out for, considerations that are often

forgotten and more, all geared to help you separate the

wheat from the chaff when selecting your controls and

components. The collective wisdom within aims to help

you winnow down the sea of available products to a more

manageable set of options. And having multiple options is

immensely important.

An automation project can often be simplified into

one big equation, and as one variable improves, another

related variable may go out of whack. Keeping things in

balance is key. You will have to adeptly manipulate the

whole project with a constant eye on the big picture, and

what you’re truly trying to achieve, rather than the best

incremental solution for each incremental problem. An

automated solution is greater than the sum of its parts.

But as a manufacturing professional, you know needs

of the day and the requirements from your customers

are constantly changing.

So, when you’re shopping for controls components,

you aren’t ever really just shopping for today’s needs.

Will your volume double over the coming year? Do

you deal with seasonal variation that means demand

goes down in spring? Do you need something that’s

dialed in to a huge volume of a certain optimum speed

or weight, or will you need a more flexible solution to

handle those shorter runs that you’re seeing so much

more frequently?

These are the questions that this handbook addresses.

These shortcuts, workarounds, pitfalls to avoid, and easily

overlooked considerations can simplify an otherwise

arduous product selection process. I hope you find this

helpful as you embark on your next automation project.

Good luck!

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16 secrets to selecting and implementing sensors in industrial applications


CONTINUED 16 secrets to selecting and implementing sensors in industrial applications

1. MEASURING RANGE. When choosing a sensor (pressure, temperature, analog, etc.), the measur-ing range should directly correspond with the physical measuring range in order to obtain the most accurate reading and optimum sensor lifespan.

For example, to measure 0-10 psi pressure range, a pressure transducer with a sensing range of 0-10 psi is most suitable. Same concept applies for voltage or resistance analog signals.

2. WEATHER WATCH. Be aware of environmental conditions when installing equipment. As an ex-ample on one project, the intake air ducts on air handler units were installed facing southwest, with no grating or gooseneck. The ducts faced Lake On-tario and would be susceptible to lake-effect snow. If the ducts filled with snow, it would impair the operation of the air handler and the sensors within the ductwork.

3. LOAD CELLS IMPORTANT. No one gives load cells the credit they deserve when it comes to level mea-surement in tanks. They work great for batch measurement applications when using a hinged tripod tank mounting arrangement: two legs with hinges, the third with a load cell in compression. Use a panel meter with discrete output to give an output when the set point is reached. This also works well for providing a low-level alarm in applications. The load cell and controller can make it simple to automate the process in the future.

4. NEED FLEXIBILITY. When choosing a sensor, consider whether it provides the flexibility re-quired, such as features that adapt to changing product. In this case, con-sider capacitive sensors, which are sensitive to more colors and materials than others, and in many cases are less expensive than ultrasonic sensors.

The successful application of sensors depends on selecting the right technology for the application, the variables of the product being sensed and the conditions in the operating environment.

The most common mistakes in sensor applications include failing to select the most appropriate sensing principle/technology for the task, and failing to consider the full

range of expected operating conditions.


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Don’t overlook critical details about environmental conditions when choosing a photoelectric sensor. Typical selection criteria include sensing range, electrical output, connection type, etc. However, in order to get the best results, sometimes users need to go beyond these basic criteria and include other critical details. These factors often end up as some of the most important considerations.

1 Are there sudden temperature changes (condensation can build up on the lens)? Some sensors are more immune to internal condensation than others.

2 Is it an extremely dusty environment? This can be particularly challenging if the sensor is mounted looking up. Consider mounting the sensor to look down. Another option would be to select an infrared LED sensor, which is better at seeing through dust and fog than a standard red LED sensor. Sometimes users will even direct an air purge at the lens to prevent accumulation of dust or particles.

3 Are the sensors mounted outdoors? It is important to know the maximum and minimum temperatures to which the sensor will be exposed. For extreme environments, an internal or external heating or cooling unit may be necessary. Sometimes a heating unit is advantageous to reduce frost or fog build-up on the exterior of the lens.

4 Will the sensor be exposed to wash-down conditions? Choose an enclosure with the appropriate NEMA/IP enclosure rating. Consider hygienic requirements in sensor selection, since these are becoming more popular in the food and beverage industry.

5 Is the sensor exposed to direct sunlight? During sunset or sunrise, for example, the sun might shine directly into the receiver of a sensor and give a false output. Reduce the risk of this happening by using a hooded bracket to minimize interference.

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5. SELECT FOR TECHNOLOGY, CONDITIONS. The most common mistakes in sensor applications include failing to select the most appropriate sensing principle/technology for the task, and failing to consider the full range of expected operating conditions. For example, although a capacitive proximity sensor can detect metals, in general an in-ductive proximity sensor would be a better choice. Ambient light, tempera-ture, dirt, vibrations or other conditions can affect sensor. An example of failing to consider operating conditions would be to install a sensor rated for a maximum temperature of 70 degrees C in an area where temperatures can reach 85 degrees C or higher. In this case, the sensor may experience premature failure or may exhibit unstable operation, such as locking on or locking off. Additionally, sensor life can be extended in harsh environments when used with accessories that are designed to protect the sensor.

6. MORE SENSOR TIPS. If changes are required, ensure proper calibration and document it in the software changes in the DCS. A built-in display unit for local monitoring of process data is recommended. Follow selection guides and material. Install the sensor in a proper rack/enclosure if the dust level is high. Put proper tags at the site to guide servicing. After commissioning, put the instrument on continuous monitoring/trending to make sure readings are correct and the calibration is accurate before handing it off to operations personnel. (Jeanne, make this one last.)

7. FAULTY CABLES. When replacing a “bad” sensor in an existing field application, be sure to also check the condition of the quick disconnect cable or cord set. In many cases, the pins or sockets are weakened or corroded, leading to intermittent opera-tion. Replacing only the sensor may temporarily restore electrical contact, but it will certainly fail again because the root cause, a faulty mating connector, has not been corrected. Depending on the cost of the sensor being replaced, this can be a pretty costly situation when in fact a relatively inexpensive replace-ment connector cable could have solved the problem in the first place.

8. DIGITAL LOWERS COSTS. If linear or proportional output sensor devices are needed, avoid analog field devices to minimize cost and support issues for shielded cables and ground-ing. When available, digital output equivalents are usually worth the addition-al purchase price for overall lower cost of ownership.

9. BEWARE OF BLUES. Too often, engineers select the sensor they know best for every job. In many cases, this presents no problem. At other times, it can be a real headache. For example, when using diffuse-type photoelectric sensors, color variations can cause serious sensing issues. This is especially common with blue targets, as they tend to absorb rather than reflect the light emitted from the sensors. A good solution for this problem is normally to use barrier-type sensors, such as through-beam or retro-reflective sensors. These can pose other problems, however, when there is insufficient space for mounting, since both technol-ogies require mounting either a sensor or reflector on both sides of the pro-cess. Another good solution for such an issue is a background suppression sensor. This approach normally uses either a fixed or an adjustable mechan-ical angle as a means to control what is considered acceptable in terms of distance from the sensor via the amount of light reflected at one particular receiver of the usually two or more located in the sensor housing. However, with irregularly shaped items, this technology can also be problematic due to light scattering. For instance, bottles and cans with the rounded surfaces can trigger the sensors, especially when it is not possible to mount the sensor perpendicular to the process due to space limitations. As a result, the sensor can false trigger. New sensor technology can solve these issues. Sensors that perform as a retro-reflective sensor, without requiring a reflector, can handle the variations in color, and irregularly shaped or spaced objects. Rather than the traditionally required reflector, the sensor uses a wall or a piece of the machine as a reflector. Any object that interrupts the beam between the sen-sor and the target triggers an output.

10. REAL-TIME PROCESSING. Decoupling measuring circuits from microcontrollers will enable real-time



processing of parametric time series along the entire operational process and provide integrated monitoring of multiple potential failures or malfunctions.

11. SUPPLIER HISTORY. When it comes to sensors, especially safety sensors, the key is finding a supplier that has a long history of safety applications and can provide any configuration and especially any IP level.

12. CHECK CONSTRUCTION MATERIALS. Proper material of construction for the service environment is important. With so many options, choose the most common and agreed upon ma-terials for longer service life. Once ordered, confirm that the material of construction is what you requested before installing.

13. VERIFY VENDOR CLAIMS. Most manufacturers appeal to engineers regarding the high reliability of in-struments and sensors these days. To verify that the claims are true, check the facts with 3rd party reviews and award programs for best practices. Practice summarizing the information as if someone wanted you to qualify your decision on the brand and model. If it doesn’t happen on the job, do

it anyway. It’s a true professional practice and you get better every time you do it. Engineering reviews (voice of experience, lessons learned) help to verify the required precision has been followed if interlocks, alarms and safety critical devices are to be used with the sensor.

14. CHECK THE RANGE. Make sure the sensor is appropriately sensitive. Target the midpoint of a sen-sor’s scale for the intended operating condition, since the sensor’s range is im-portant. The application is only as good as the detail you bring to the table.

15. ELIMINATE BOTTLENECKS. In-motion weigh scale systems can create a bottleneck in an automated shipping and delivery line. Alleviate them with parallel stations.

16. SYSTEM CONFIDENCE. Check the functional specs when selecting safety-instrumented systems. Failure rates (MTBFs) are very critical in keeping confidence in a sys-tem high. Maintenance intensive calibration and servicing requirements should be recognized.


36 best practices for specifying PLCs, PACs or PC controllers


http://www.beckhoff.us/EtherCAT-System


CONTINUED 36 best practices for specifying PLCs, PACs or PC controllers

1. BENCH TEST. When working with a controller, it’s important to know its capabilities and if it meets the needs of your project. There’s nothing worse than being halfway through the project, only to find out that your controller isn’t capable of do-ing something. If the project includes something you haven’t done before, always bench-test the process before committing it to the project.

2. DON’T OVER-SPECIFY. Don’t select a specific controller too soon in the design phase of a project. Selection should occur only after the initial machine or process automation conceptual design is completed. Far too often an over-specified controller unnecessarily adds to the automation project’s costs. Or even worse, an un-der-specified controller may result in redesign efforts, additional purchases and schedule delays.

3. CLARIFY INTERFACES. If multiple people program parts of the PLC code, spend some time initially to make sure that the interfaces are clear and everyone understands them. Dumping a diagram on someone is not good enough.

4. NO CANNED CODE. When planning for PLC-based controls, if your in-house techs will be in-

volved in maintaining and upgrading the new system for future needs, don’t bring in “canned code.” Ensure that your techs have input as to the structure and nomenclature of the program. Bugs and changes are the norm with any new control system, and you will find your facility rebounding much quicker after such a major change in equipment.

5. CAN WE TALK? A primary concern when implementing any PLC is communications. This has been minimized with the advent of ODVA, but can still be a problem when dealing with some sophisticated sensors or peripherals. Choosing a PLC fam-ily that has all the device type communications modules is paramount. Most PLCs on the market can communicate on device buses, but not all can ac-commodate every type of Ethernet. Do your homework and choose a PLC that can support all your buses without a lot of pain.

6. NOT ALL CONTROLLERS OR BRANDS ARE THE SAME. Consult with people who are knowledgeable in many different hardware platforms before specifying or selecting a certain make and model or even a platform. Too many times what is specified will not perform to the customer’s expectations. That leaves gaps in what is bid and will require changes in the project.

The controller is the foundational product for any automated system. Whether it’s based on PLCs, PACs or PCs or a combination, your control platform must perform reliably for many years. Quality, functionality, cost, ease of programming and maintenance, the ability to communicate and connect with multiple devices on the factory floor, as well as ready availability of support from the manufacturer, all factor into the selection process:


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7. KEY CHECK POINTS. Whenever upgrading a system or changing from one controller to another, always remember to check the controller’s power supply, memory, I/O type, size and availability in the panel. Double-check the purpose for which the controller is intended, and always carefully check the model number. Make sure the controller has the basic features you want, such as online bypass, online programming, alarm management or closed-loop control.

8. HMI FIRST. When programming your project, it’s best to start with the HMI first. If you write your program code first, quite often you’ll have to rewrite your code to accommodate your HMI.

9. CPU LOAD. It is important to consider the CPU load if communication handling is vital to

the application. Running at the maximum cyclic load will result in poor ca-pacity and response times for peer-to-peer and OPC Server communication.

Peak cyclic load should be kept below 65 percent and static cyclic load be-low 60 percent under all conditions. Even lower cyclic loads (30-40 percent) are desirable if high communication throughput is important. 10. Get out of the code. Ask the people at the plant why they are running the way they do. Sometimes what you might think is bad programming is really needed to op-timally run a process. On the flip side of the coin, after examining the code, you often find people think a system is running in a particular way, but the reality is that it is not.

11. DOCUMENT SOFTWARE. Use of programmable controllers offers significant advantages over analog devices. However, it brings a new set of issues. First, consider the control of multiple function block parameters. It is a good practice to maintain the soft-

Driven by competitive pressures and technological advancements, machine builders are increasingly taking a holistic approach to building automation technology into their machines. Many OEMs are turning to micro PLCs for flexible, ‘just-enough’ control to help them differentiate their machines from the competition, especially in stand-alone machines.

However, the PLCs must be economical from a total system perspective. Machine builders commonly want to develop a range of stand-alone machines using

the same controller platform to save design time and consequently lower their costs. Micro PLCs could be a useful solution if they meet the following requirements:

• Flexible hardware configurations, like USB, up to 6 serial ports and Ethernet for communications

• Up to 3-axes of embedded motion• Plug-ins and 2085 expansion for I/O USB• Single programming software package that

simplifies installation, configuration, connectivity and maintenance

Micro PLCs: A solution for OEMs?



After the main project scope and interoperability foundation have been determined, spend time familiarizing yourself or others working on the project with the total costs of programming, installation, life cycle maintenance and repair before purchasing of hardware, software and training.

The overall cost of hardware can in general be fixed and there are many options and price points available, but this hardware is useless if the programming software is difficult to learn, use or get support and training for. Simply because the hardware is purchased from a well established firm does not guarantee the software will be workable with either the project parameters or the personnel expected to use the software in the field.

The learning curve for programmers and maintenance people can exceed the cost of the original purchase and installation of the project if this factor has not been properly considered and given a real and definable cost. Additionally, the technical support available from hardware suppliers for their software users is widely variable. While it may be difficult to determine the real costs, it is critical not to overlook the cost of support since it will be needed on an ongoing basis for the entire lifecycle of the project.

The best, most capable software is useless if the programmer or maintenance people need to have extensive schooling from the supplier just to use that version of control software or if the technical support provided is difficult to access or must be purchased.

Examine total costs

ware configuration control document that summarizes all programmable/tunable parameters in one place. You will use this document for any disaster recovery event, including cyber-security issues.

12. THINK AHEAD. Don’t go for the cheapest option when installing a PLC. Think five years ahead to accommodate factory integration, peer-to-peer networking and data ex-change between controllers. The modern factory environment is becoming a network of integrated controllers.

13. DON’T OVERCOMPLICATE YOUR SOLUTION. Keep it as simple as possible. Don’t use a PC-based system when all you need is a little advanced I/O control.

14. PRIOR EXPERIENCE. Do not use a controller for critical applications in your plant without a suc-cessful prior use experience with a like product with the same revision level components, firmware and software.



15. ARE MICRO PLCS AN OPTION? Micro PLCs with flexible, “just enough” control may enable OEMs to differ-entiate their equipment, particularly in stand-alone machines. By developing a range of stand-alone machines using the same controller platform, OEMs can reduce design time and lower their costs.

Look for micro PLCs that include:• Flexible hardware configurations, like USB, up to six serial ports and Eth-

ernet for communications.• Up to three axes of embedded motion.• Plug-ins and 2085 expansion for I/O USB.• Single programming software package that eases installation, configura-

tion, connectivity and maintenance.

16. SINGLE CONTROL PLATFORM. Customizing your controller selection for each application may seem like a smart move, but sometimes it pays to narrow down to a single control plat-form. Survey your requirements and select a platform capable of handling all current and near future needs, from the simplest to the most complex ones. Selecting a single control platform for all of your automation control require-ments, whether it is motion, robotics, numerical control, C program or se-quence control, can reduce spare parts inventory, unify programming meth-ods across all machine types and simplify training and maintenance efforts.

17. KEEP IT COOL. When designing a redundant PLC system, remember to provide sufficient cooling of the power supply, CPU and communication processor modules by using a special fan (or fans) below the modules.



18. COMPARTMENTALIZE. PLC programming is a lovely fossil. If used properly, it can be a stroke of effi-ciency or a tangled web. Compartmentalize your programs to form sequenc-es with dummy addresses. This keeps the sequences straight and makes it possible for different parts of the program to use the same inputs and out-puts. It also makes it easy to find where glitches are located in the program.

19. USE A COUNTER. When two or more high-speed bits have to be checked to ensure they are all on, use a counter instead of the traditional latch. The latch only tells you it happened at least once, whereas the counter will indicate if it happened with each part made, or more or less often. This allows you to see if the suspected inputs are not being made when required. Count the number of parts made, check your bits state counter and they should compare.

20. ALLOW CHOICE. When working with a supplier, do not force them to use a PLC they have had no experience with. If they have been successful using a particular brand of PLC, even though you may need to expand your spare parts, forcing them to use another product and still meet deadlines will most likely result in an inferior system.

21. CAN IT CONNECT? Make sure the PLC you use can connect to the hardware you are looking to interface with. This is especially true for drives, RFID cards, and radio modems.

22. MANAGE TIME. When a PLC/PAC needs to deal with many different tasks, the CPU time slice assignment is important, such as: motion, periodic task, critical (peer-to-peer) communication with other PLCs, and HMI or monitoring tasks. Here the mo-tion task is most critical. Use a SERCOS ring for 3 axes; selecting a 4ms cycle time can be a reasonable choice. Selecting a shorter duration may overbur-den the CPU with other tasks, especially if there is a slow response time in the HMI display. Unfortunately, there is no powerful diagnostic tool for this issue.

23. DON’T JUMP. Try to avoid “jumping” within your code, i.e. going from line 2 to line 7 and/or line 10 to line 4. Keep in mind that someone else may have to review your code in the future and it has to be comprehensive. Better yet, use program-ming templates so that the locations for the code can be accessed easily depending on the state of the machine.

When planning for PLC-based controls, if your in-house techs will be maintaining and upgrading the new system for future needs, don’t bring in “canned code.” Ensure they

have input as to the structure and nomenclature of the program.



24. LAB TESTS. When scoping a PLC or PC job, order additional hardware for a lab-based system representing the production system. Upgrades are a never-ending cy-cle, and developing/testing upgrades in the lab ends up reducing downtime and lost production.

25. NO EMPTY DATA. In PC to PLC data collection, signal timing and handshaking are critical. If the

PLC sets a Boolean bit when data is ready to be collected (end of cycle bit, for example), logic should exist to ensure no empty / null data exists in the de-vices to be read prior to setting the bit. String processing, complex math and other functions can delay PLC values updating. Failure to confirm can result in missing data. On the PC application side, if the application is providing a “completion response” to the PLC, the developer needs to ensure all data has been read and successfully stored / processed. This is especially true if the response bit is being used in the PLC to truncate / reset PLC data.

When selecting a control platform to automate a machine, you should first decide your end goals. Ask yourself:

1Do I want increased productivity? Better repeatability? More consistent accuracy?

2 Do I need servo or stepper motors? Servomotors will generally have better acceleration and top speed characteristics over a stepper. Stepper motors do better when holding a position without dithering.

3 What type of controller? Will a PLC work or do I need a more dedicated motion and machine controller? For basic material and conveyor control, a PLC is a good choice. If high-speed electronic

gearing, product registration or more complex motion is required, a dedicated motion/machine controller is a better choice. If data handling is required, then a more dedicated motion/machine controller would do better.

4 Will the controller do the job? Best to spec in a controller that can handle more axes of control than you expect as you may need to add these capabilities later. Be sure the controller has the processor power to perform all the needed functions. It’s common to “run out of gas” when performing multiple tasks simultaneously. Look for a fast processor, enough user memory and a lot of connectivity.

What are your goals?



26. KNOW THE INSTRUCTION SET. When selecting a processor of any type, know the key processes required for the project. If there are complex requirements, such as servo motion or PID requirements, a lot of venders will sell you a processor that is fully “integrat-ed” with these systems. Unless you are familiar with what the instruction set offers for that processor, however, the vendor’s idea of integrated commands might not be very user friendly.

27. LOGIC TIPS. Utilize standard code to decrease downtime. Organize code so devices are easy to locate. Create logic to quickly outline reasons a device/function is not working. Don’t attempt to fix bad code from the previous vintage...start over.

28. EMBRACE ISA 88. The ISA 88 principles are applicable to both batch and continuous processes, providing an elegant and flexible solution. Say goodbye to spaghetti code.

29. DESIGN FIRST. Designing your software to be modular and to be arranged in layers (hard-ware through supervisory) before starting to write is an absolute must.

30. COSTLY SOFTWARE. Watch out for unfavorable initial and sustaining software licensing models and costs that can make a given controller system undesirable.

31. SINGLE VENDOR SOURCING. The main challenge in new PLC installations is the wide variety of protocols for I/O and motion control devices. The best solution is to install single ven-dor components.

32. FAIL-SAFE. Controllers should be programmed to be a stand-alone system to ensure that failure of communication with the HMI will not affect the process. Any failure of the controller should put the system and process in a safe state, known as a fail-safe condition. Scan time, process time and action time of the controllers are priorities for a robust control system.

33. ALIGN WITH STANDARDS. Define the inter-PLC communication requirements and ensure that they are implemented consistently across all the PLCs in the project. If the PLCs are for machine control, alignment to the OMAC and PackML standard will greatly improve usability and maintenance.

34. UNIVERSAL CONTROL PLATFORM. Having multiple control systems interacting with one another in a factory can cause major problems. Because of all the different systems, simple issues can become very difficult to troubleshoot, and very costly when bringing in external support. In most cases, custom machine integrators will use the controls platform of your choice. Standardize on a control platform across an assembly project and in your factory. It will save money in many ways, from minimizing downtime to reducing spares inventory.

35. CHOOSE QUALITY.For general automation systems, choose quality controller systems with the main features you need, but especially with a good reputation for ease of use and maintainability. A few man-days spent wrestling with programming, test-ing or startup issues will quickly chew through any initial hardware savings. The PLC should make it easy to create a back-up file of firmware and recipes, including data from servomotor positions and production processes.

36. CHECK DAILY. Automated tests for embedded software are extremely useful. Checking all software features on a daily basis is a very good way to guarantee that fea-tures don’t suddenly break, caused by a little change done by someone in an apparently unrelated part of the software. Having problems revealed within one day ensures that they get fixed quickly, as the person who made the bug still knows what he did yesterday.

Better quality software takes the heat away from customer support departments.


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CONTINUED Nine essentials to consider when building out an industrial network

1. KEEP A LIST. Networked devices have addresses. It is very important to keep a list that shows the assigned address, the product this address has been assigned to and the line/plant location where the product has been installed. It is very dif-ficult to troubleshoot many systems because this basic information was not captured, leading to significant equipment downtime. Once installed, these devices need to be labeled accordingly since it is not uncommon to have several identical devices in close proximity. This information should also be part of any electrical and mechanical drawing.

2. TEST TO FAILURE. When developing data collection/data passing applications (PLC to PLC, PC to PLC, etc.) using Ethernet, fieldbuses and especially proprietary networks, it is critical to test to the point of failure. These failure points can be associated with the number of Ethernet port connections, the size and frequency of data being managed, as well as data addressing in the PLC. The PLC addresses used in data collection, if not contiguous or near contiguous, can cause excess read/write cycles to the PLC. Some PLCs can only provide X number of devices in one read. If that number is 1k (1024 devices) and you attempt to read the values of coils 250, 1400, 5000 and 6500 in one cycle, it can actually create four sep-arate read requests. This results in performance issues and missing data. Think of the impact if you want to read 250 values! FMEA (Failure Modes and Effect Analysis) is a great tool to aid in trying to identify ”what can go wrong.”

3. BE AWARE OF SECURITY ISSUES. You have to be constantly aware of the security aspects of your control net-work. Seek cooperation with the IT professionals; you likely have more over-lap with office systems than you might know.

4. AVOID SUBNETWORKS. When selecting fieldbus or network architecture, avoid the use of subnetwork systems or expandability features that require configuration of expansion modules or field devices separately from the PC or PLC. Subnet components add an additional burden for end-user support and complexity in software (re-tagging/programming) when the subnet I/O count or type changes.

5. NEED NETWORK ANALYZER. When a system using a fieldbus/industrial network does not work as expected, somehow the network is always blamed: too slow, too many flipped bits due to EMC (electromagnetic compatibility) issues, etc. Without proper measuring equipment, a network troubleshooter won’t stand a chance of disproving this. Make sure high-quality network analyzers are available, and the real root cause of the problems will show up very quickly: very often it is application software. A network engineer without a network analyzer is like an electrician without a multimeter: clueless.

6. EVERYTHING’S NETWORKED. Nothing is not in the network anymore. When you implement a new project or a new system, the networking criteria are a critical consideration. Every de-vice needs a communication port or ports, physical media, communication protocol and tools to configure, display, diagnose, analysis, etc.

7. SEPARATE CABLE ROUTE. To have a more reliable DCS system in factories, use high-quality network and fieldbus components and make a separate route for network cables. This will help guarantee system performance.

It all comes down to the details. That’s as true for networking as it is for every other aspect of an automation project. Here are some tips for making sure the details are covered with your industrial network:


CONTINUED Nine essentials to consider when building out an industrial network

8. MATCH MEDIA TO CONDITIONS. There are a variety of different types of network connectivity. Choose the media according to the environment and conditions under which this net-work will operate. As an example, you would not use Cat6 wire for an Eth-ernet communication between buildings. Use fiber instead due to lightning conditions. You could also use wireless modems instead of fiber when the distances between buildings are great.

9. PROTECT SENSORS ON MOBILE EQUIPMENT. When using wireless in a dynamically changing production process where machines or sections of a production line are moved frequently, protect sensors mounted on machines with enclosures that prevent workers from removing them. This solution is also helpful in preventing damage to the sen-sors when moving equipment.

OEMs need to understand the big picture when selecting a network for a machine. Does the end user of that machine need secure remote access, will IT be involved, is the machine standalone or will it be networked? How? What are the requirements?

In today’s factory, departments such as IT, operations and accounting will likely be involved in the project scope. You need to understand their requirements when selecting a network and how to provide value after the machine has been delivered.

Machine builders also need to consider how their equipment will impact the factory LAN once the customer installs the equipment on the factory floor. Many OEMs now use Ethernet as their communication protocol within the machine and provide an Ethernet switch to network the devices in the panel and to

provide a link to the factory floor.

Several of the industrial protocols on the market today use multicasting between devices in order to streamline communication. This feature can save bandwidth within the machine by allowing a device to send one packet to several devices at once, but can cause problems with the factory network if not handled properly.

If an OEM puts an unmanaged switch on the machine and the customer connects the machine to the factory LAN, this multicast traffic will be broadcast throughout the factory because an unmanaged switch will turn that multicast traffic into broadcast. The solution is to use a managed switch that supports both IGMP and IGMP snooping on the machine. This will prevent the multicast traffic from reaching the factory LAN.

Networking tips for machine builders


17 product selection steps guaranteeing I/O engineering success


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CONTINUED 17 product selection steps guaranteeing I/O engineering success

1. MOTION NEEDS DETERMINISTIC I/O. Try to have deterministic data transfer. If motion is I/O-sensitive, then you need deterministic I/O to synchronize to the motion task, so that events hap-pen in the same time interval.

2. QUICK CONNECTIONS. When selecting a terminal block for your control cabinet, look for one that has pre-built jumpers that can be installed quickly. This will save time later.

3. MATCH SPECIFICATIONS.It’s important to know all the information about any components you are interfacing to when you develop specifications for a project. If others are supplying parts, find out whether they are NPN or PNP, if analog signals are voltage or current, any handshaking requirements and dry contact digital or higher-level communication. It seems simple, but one key component that doesn’t match up with the I/O you select can cause big headaches.

4. FIELD ELECTRONICS. Ensure that I/O electronic interfaces can be implemented directly in the field, allowing you to replace the junction box multi-conductor back to the equip-ment, rack or MCC room. Field electronics need to be G3 rated per ISA stan-dard (S71.04).

5. SHORTEN COMMISSIONING. I/O allocation plays a key role in reducing the commissioning duration of an automation project, followed by appropriate loop testing prior to start of com-missioning activities.

6. DELAY LAYOUTS. The design team working on the project should not begin the planning and layout drawings for distributed I/O in the facility until all equipment OEMs have provided general arrangements. Provide the team with an overall scope on what these cabinets are called by name, and what area of the facility each will handle. Timing of this design phase with the upfront engineering will save time and money.

7. LEAVE ROOM FOR EXPANSIONS. Make sure your new control cabinets have plenty of room for all I/O points needed in that cabinet. Also allow room for expansions that will be required for unanticipated changes and upgrades in the future. For I/O wiring, plan to label the parts of the circuit wiring that connect to the I/O points from that side of the devices with the program addresses. This will lessen the time needed for your techs to troubleshoot issues with those circuits later on. The rest of the circuit labeling should be based on the print line numbers.

The days when every device in an automated system had to be installed using multiple wires are over. While proper system design can still be challenging, technology advances in I/O have greatly reduced engineering and installation time and the wiring errors that once caused frustrating delays in the commissioning of new automated equipment.


CONTINUED 17 product selection steps guaranteeing I/O engineering success

8. DIAGNOSTICS. Make use of the built-in diagnostic information provided by most I/O systems. Good information for the operator can save you a lot of production time.

9. BUNDLE COMMONS. Make sure all commons are bound together to avoid transient voltage fluctu-ations and erratic signals.

10. DISPLAY I/O STATUS. Always represent the I/O status on the HMI display to allow fast identification of a communication problem in the remote I/O. This will reduce reaction time and allow factory personal to more easily provide service.

11. SUPPORT PROTECTION. Use an I/O technology that has support for both IP20 and IP67 protection in all signal types needed. This would include illuminated LED ring key opera-tor stations, pneumatic valve controllers and operator stations that eliminate hard-wired push buttons and indicators. Link them all on a single digital field-bus.

12. REQUIRE PLUG-IN WIRING. While plug-in I/O modules are common today, some suppliers still offer wired modules. Whenever there is a module failure, it takes about 10-15 min-utes to replace a module with terminal wiring. This increases plant downtime. Always insists on I/O modules with plug-in wiring. While more expensive, the initial capital cost for pre-built termination assemblies is more than offset by the saving on engineering, construction and commissioning. These factory assembled, tested, certified and proven modules eliminate much of the typi-cal design, construction and startup headaches.

13. DON’T RETIGHTEN. It may seem counter-intuitive, but continuing to check terminal blocks to make sure they are secure will cause issues over time. The idea of retightening based

upon the manufacturer’s recommendations will actually cause the blocks to be stressed and contribute to more failures over time.

14. WEATHER PROTECTION. The design for input, output or any other modular devices must have a pro-tective type of material to protect against weather exposure and other envi-ronmental conditions. This weather-protective material will definitely extend the lifecycle of the device.

15. IS IT OFF? Recognize that electronic outputs are not completely de-energized when switched to the off position. Final elements such as pilot solenoid valves need a turn-off level higher than the output turn-off level; otherwise, the solenoid valve will not turn off.

16. PROVIDE SPARES. Design to the I/O requirements but allow an additional 20 percent to serve as design spares in case of failures during commissioning or surprise require-ments.

17. CONFIGURING INTELLIGENT DEVICES. Users of modern control systems can place their I/O close to their sensors and actuators and transport information to a higher-level controller over a fieldbus cable. The cost-savings is tremendous compared to the days when hundreds of field devices had to be wired back to a central controller with multiple wires per device. Today engineers can consider IO-Link to gain similar benefits when wiring complex end-devices. IO-Link-enabled devices not only help reduce wiring costs, but the technology allows users to configure intelligent field de-vices from multiple vendors over a fieldbus network. This eliminates the need for an engineer or technician to use a vendor-specific handheld device con-nected to the sensor for calibration or configuration procedures. If you have ever tried to calibrate a capacitance level probe on a large tank, you know the challenges of this procedure. Being able to calibrate a device over a fieldbus network greatly simplifies the process.


20 steps to creating the perfect HMI


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CONTINUED 20 steps to creating the perfect HMI

1. LESS IS MORE. It’s important to keep the HMI simple and with the operator in mind. It’s best when it’s self-explanatory and easily understood. Also, try to make the pag-es similar and follow the same page layout throughout. Avoid making the display too technical. It’s normal for engineers to try to give the customer everything, but with HMI, less really is more.

2. RIGHT-SIZE DISPLAYS. Don’t try to save money by selecting an HMI display screen that’s too small. It’s also important not to cram too much information onto a screen. Size the display according to the amount of information that is most important for the operator to see. Always discuss requirements with the equipment’s operators well ahead of time, not just with their managers. Operators usually have dif-ferent needs and the success of your system depends on their usage.

3. DESIGN TIPS. A good design requires careful use of layout, color and content. If you get it wrong, your operator misses an indication, you lose money, or worse, someone is injured. The ”bad” screen is less than satisfactory: The layout is poor, the plant representation isn’t logical and the screen layout makes it difficult to locate the data. Poor selection of colors, excessive use of capi-tals in a serif font and repetitive use of units with all data values makes this a really difficult screen to read—especially at a glance or from a distance. Avoid colors that could create problems for people with color blindness.

Minimize the use of colors to allow actual device state and alarms to stand out. For alarming, choose colors that contrast with the normal process view so the operator will notice the change.

4. PLANT REVIEW FORUM. Hold a design review with a group of plant personnel to discuss any status notifications, events, alerts and alarms that need to be programmed, both from the perspective of an audio-visual action and an operations response. Step through the intended functional system, once as the designer, once as the user and then invite at least two levels of users who will be interfacing with the HMI. Doing this prior to specifying equipment helps to identify the features that users will want in the HMI station. It also avoids surprises at point of commissioning.

5. LOCATION, LOCATION, LOCATION. Real estate can be prime in a busy production area. Locate the HMI in a prac-tical place, out of heavy traffic areas but accessible. Be aware of near-future projects in the area. Guard the HMI location so others don’t park or config-ure something else on top of the station.

6. BACK UP WORK PERIODICALLY. Backups are especially important before implementing upgrades or chang-es. Software such as Norton’s Ghost Image can be invaluable to support and maintain HMI systems.

When developing HMI screens, realize that you are attempting to capture the essence of the machine or process, not just posting key automation variables and control mechanisms. Operational feedback is vital for efficient HMI screen layouts. Think of yourself as an artist, commissioned by manufacturing operations to create the HMI screens.


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7. VISUALIZE THE PROCESS. HMI graphics should illustrate the production process in the plant to provide bet-ter visualization to the operators, giving them a sense of the action that’s required. Use hardware that meets minimum requirements and keeps the number of failure points low and assures high availability of the system.

8. ONLY ESSENTIAL DATA. Make control and monitoring of the process simpler by selecting only the most essential information from the process database for the historian. This will reduce the load on the system and keep it from stalling or fail-ing. Don’t forget the need for maintenance and make sure you schedule periodic backups.

9. THINK ABOUT FLOW. It is essential to have a clear design approach to the HMI. Decide how the display blocks naturally flow and how sections need to be grouped togeth-er for the operator. Do not blindly follow P&I diagrams. The S88 functional hierarchy is a good place to start. Make paper-based designs to get a feel for screens, navigation and other requirements, and review with clients prior to designing and making electronic screens.

10. ALARM STRATEGY. Alarming needs to have a well articulated strategy. Alarms must be used for conditions that require intervention and must have a clear corrective action associated with each one. Anything else should not be an alarm.

11. THE BEST HMI IS A ONE-LINE RHYME. An improved overview increases the efficiency of information perception. A monitor that is twice as large (as measured by the number of pixels) can im-prove worker productivity by 30 percent. The goal is to smartly arrange the ele-ments to increase information density without overloading humans. A one-lin-er is a concept that doubles down on visibility. The shorter the message, the less eye movement, the better the perception. Understand who will be using the HMI and how they work. Less-skilled operators often use large tools to op-erate displays and get impatient if the screen response time is not fast.

12. BUILD A PROTOTYPE. For each area where HMI is being implemented, select a representative area to design and plan for a formal prototype review with the project team, approving the basic functions, colors, animations, limits, screens, formats, etc. Build the prototype to verify the required user experience as early in the process as possible, and keep referring back to that basic functional requirement. If any aspect of this approved baseline changes, you have a documented basis for a scope change.

13. VIRTUAL TESTS FOR UPDATES. HMI software is at the mercy of security updates. Updates keep hardware clear of malware but can disable once-functioning subroutines. Often, this happens without warning. A second backup test server allows patch testing without effecting production. Testing in the virtual environment is very cost effective.

14. EVALUATE SUPPORT. Many companies have good products, but have generally poor experience in providing concise backup in a cost-effective way, both for the contractor and the client. All HMIs have their ups and downs, but the better the tech support, the more likely you will have a successful project.

15. HMI-PLC COMMUNICATION. Make sure you understand how to set up communications between the PLC and HMI. This can get tricky when you are not using the same manufacturer for both products. The client-server philosophy is useful in new projects. It allows more effective communications with the PLCs. 16. Mobility chal-lenges. Many people want plant data to be available for their mobile devic-es. While this is an important trend, most traditional plant floor information systems tend to be vendor-specific machine control applications and don’t really play nice with distributed data applications. Today’s web-based visu-alization and data management tools allow for a more flexible data model at a considerably reduced price point. Consult with your IT group prior to any major HMI deployments.


CONTINUED 20 steps to creating the perfect HMI

17. OFF-LOADING PROBLEMS. Manufacturers are creating HMI products with more capabilities that allow off-loading from the PLC program. The problem is that this leads to the ma-chine program residing in two locations. This complicates troubleshooting. An HMI is great for scaling the data from user to PLC format, but if you move too much of the functionality to the HMI, problems arise.

18. STANDARDIZE. Select one HMI platform for your entire plant, process or machine that is independent of any particular controls architecture. It’s easier for the op-erators and reduces the back-up hardware needed on site. Operators and programmers become very familiar with the look and feel of the graphics, projects and operation of a touch screen. Develop your own standards. If you rely on vendors, you will get a mess of all different looking systems.

19. CROSS-CHECK ALARMS. Operators need assistance and audio alerts, not nuisance and noise. Always revisit the alarm list after pre-commissioning at a plant. Configure alarm alerts only after crosschecking with another independent alarm. For exam-ple, crosscheck a high-flow alarm for the reactor input with one for a fall in the level of the tank. If both match within the acceptable limit, an audio-vi-sual alarm should appear as an action point. ISA 18.2 is a good guide for categorizing alarm management. If an HMI alarm is not applicable for the

current operating mode of the process equipment, it should be deactivat-ed automatically without operator intervention. Not more than 10 alarms should be standing on the alarm page or else it will be impossible for the operator to keep track of the process.

20. MULTI-STEP PROCESS. HMIs are the user’s eyes and limbs to a process control solution. Do your homework before starting implementation and understand how the pro-cess works:

• Study the problems, understand the cost and time constraints, who will use it and why.

• Determine the best architecture: single/multi screens, local/ remote, usability.

• Define the hardware parameters: hardware selection, data connectivity, response times.

• Establish software parameters: screen layout, navigation, objects, alarms, event handling.

• Implementation issues: ergonomic considerations, accessibility, mark-ings. Documentation: do not leave this out; it is an integral part of the project.

• Training: prepare to teach plant personnel how to use the solution.• Follow-up: post project review, usability, effectiveness, troubleshooting, etc.)

Select one HMI platform for your entire plant, process or machine that is independent of any particular controls architecture. It’s easier

for the operators and reduces the back-up hardware needed on site.


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CONTINUED 11 recommendations for selecting motors and drives

1. THINK SYSTEM. When doing an equipment upgrade, think of the drive train as an integrated sys-tem and choose components with similar efficiency ratings. It makes no sense to couple a high-efficiency pump to an inefficient worm gear. The motor used to drive the load could be half the horsepower with a more efficient gear reducer because of the reduced energy losses.

2. MATCHING FIRMWARE. When changing a drive, make sure the firmware of the drive or motion control-ler matches the one you are replacing.

3. INTELLIGENCE IMPROVES UPTIME. When you want to improve uptime, think about replacing standard IEC elec-tromechanical starters with an intelligent overload with a hybrid contactor. Now you have the best of both worlds—a programmable, intelligent overload that has motor load feedback (alarm back to operator as well as shutdown parameters) with a hybrid contactor. The hybrid contactor extends the time between end-of-life motor switching by a factor of 10. The intelligent over-load will remain in service indefinitely.

4. PROPER WAY TO SELECT MOTORS. Selecting a motor needs a bit more than just calculating the maximum rota-tional speed and torque. The best way to select a motor is by drawing a speed-torque diagram of the load and the maximal allowed speed-torque diagram of the motor (as defined for continuous operation). If the diagram of the load characteristics is fully enclosed by the diagram of the motor characteristics, the motor is adequate.

5. MANUAL MODE. The manual mode, which allows maintenance to check if one specific motor has a problem or not, is usually forgotten. If the motor will not run correctly, put the drive into manual and run the motor for a short time. This eliminates the drive from the problem and points to the controller or, if local control does not work, the drive could be suspect.

6. DO YOUR HOMEWORK. Always check for the proper rating and proper type of drives or motors for different type of application. Ask the supplier about the fail-safe function of the system and always check for proper grounding of the system. Make sure you inform the supplier about the features you want and the process to be controlled.

7. MAGNETICALLY COUPLED DRIVES. For variable speed control of rotating equipment, such as drives for an agi-tator motor or a chiller compressor, take special care to place the drive in a hardware panel installed in a dust-free location, preferably air-conditioned. A better solution for harsh environments that have maintenance people with minimum skills might be a magnetically coupled drive with variable speed option. Magnetically coupled drives have the advantage of decoupling of vi-bration and potential overloading of the motor or driven equipment due to the air gap between the motor shaft and the other shaft, which can reduce costly damage to mechanical seals on equipment.

Motors and drives are two of the foundation components of any automated system. Here are a few tips and best practices for achieving improved motor control:


CONTINUED 11 recommendations for selecting motors and drives

8. ECONOMICAL SPARES. Try to use the same type of drives to maintain a common inventory. Also, in-stead of stocking multiple spare cards for the drive, keep one spare module. This will be an economical solution.

9. DECIDING FACTORS. With the sophistication of drives technologies, it often becomes difficult to de-cide what to choose as the right technology for positioning applications. In the past, servo systems were the only choice available for achieving reliable positioning performance. Today, however, many applications, excluding CNC machines, can be implemented using AC flux vector drives. The determining factor in the final choice of technology is the positioning accuracy require-ments and the ability to deliver full torque at zero speed.

10. DRIVE FAILURES. The reliability of the core components, such as the PLC or a variable fre-quency drive, in a control system is important. Drive failure may be caused by many factors: PCB calibrating, IC chips failure, mishandling during instal-lation, operating environment, etc. Even though the manuals of some drives claim that using certain technologies, such as MOV, common mode choke, common mode capacity and others, can make the drive more EMI compati-ble, it can also make them easier to damage.

11. GOOD HOUSEKEEPING. Keep motors and drives clean and free of foreign contaminants to keep them running for along period of time.


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