PLCs From Control Engineering Fall Edition

PLCs
FA L L E D I T I O N
Contents
3 — Structuring with IEC 61131-3: 7 steps to success
12 — CLICK PLUS PLC vs CLICK PLC
13 — Micro PLCs versus Programmable Relays
25 — PLCs power industrial data integration
34 — PLC software benefits for industrial manufacturers
36 — Should I use an edge controller, PLC, or PAC?
47 — The PLC remains stronger than ever
50 — PLC users can use cloud services without programming
2
Structuring with IEC 61131-3:
7 steps to success Structuring with IEC
61131-3: 7 steps to
success
The IEC 61131-3 standard includes powerful structuring tools and can
CLICK PLUS PLC vs CLICK
help provide users an excellent way to break a control system down into PLC
manageable units for greater overall effectiveness. Micro PLCs versus
Programmable Relays
A s needed for a modern software development environment, the IEC 61131-3

programmable controllers, part 3 programming languages standard from the
International Electrotechnical Commission (IEC) includes powerful structuring tools.
PLCs power industrial data
integration
PLC software benefits for

The essential parts for this are sequential function charts (SFCs) and user-derived industrial manufacturers
function blocks. Both provide an excellent way to decompose a control system into
Should I use an edge
manageable units. controller, PLC, or PAC?
The PLC remains stronger

These units are easier to use and understand by different people with different back-
than ever
grounds. It provides the missing links among system engineers, software developers,
PLC users can use
and installation and maintenance people. In addition, it provides a representation
cloud services without
and communication tool for these different groups. programming
In this way, multi-disciplinary teams can cooperate in larger application programs,

generating more easily understandable and reusable code, and providing a separa-
tion among different levels of programmers, installation and maintenance people,
and users.
Also, the section of error detection and error processing can be dealt with in an early
stage of the software development. The alternative, to create these sections during
installation – or even during operation – is too expensive for the supplier (in support)
3
Structuring with IEC 61131-3: 7 steps to success
as well as the user (in Structuring with IEC

downtime).
61131-3: 7 steps to
success
Providing PLC
structure for
Micro PLCs versus
control system Programmable Relays
programming PLCs power industrial data
The advantages of integration
structuring control
system code are industrial manufacturers
broad and include:
controller, PLC, or PAC?
• A better over-
view of the than ever
Figure 1: Example of a fermentation
system, not only important for the original pro-
process and its control system. PLC users can use
grammers, but also for the installation and main- Courtesy: PLCopen cloud services without
tenance personnel; programming
• A better basis for internal communication within the multi-disciplinary develop-

ment team;
• A clear separation among different responsibilities;
• A better focus on the real problem and possible solutions;
• A basis for reusable software.

4
Structuring is done via Structuring with IEC

dividing the problem into
61131-3: 7 steps to
success
smaller parts, which can be
sub-divided. There are lim- CLICK PLUS PLC vs CLICK
PLC
its to this: it is not practical
to continue to an endless Micro PLCs versus
Programmable Relays
fine granularity, since the
effort of the integration of PLCs power industrial data
integration
these parts is increased.
industrial manufacturers
The use of modular blocks
is associated with five prin- Should I use an edge
ciples:
Figure 2: Read from left to right. On The PLC remains stronger
the left are the inputs, on the right the than ever
1. The programming language should support the outputs. Courtesy: PLCopen
modular units. PLC users can use
programming
2. The units should be composed in such a way and in such number that they have
few interfaces and few interactions.
3. The interfaces should be small, needing little data exchange.
4. The module interactions require explicit definition, to increase their re-usability.
5. The modules should provide data encapsulation: the application data is par-
titioned, and each partition should only be accessible by a proper set of func-
tions, which hide it from undesired uses. 5
Seven steps to success for structuring programming software Structuring with IEC
61131-3: 7 steps to
The following 7 steps provide a road to success for the structuring of control system success
programming software:
PLC
1. Identification of the external interfaces to the control system.
Micro PLCs versus
Programmable Relays
2. Definition of the main signals exchanged between the control system and the
rest of the plant.
integration

3. Definition of all operator interactions, overrides and supervisory data.

4. Analysis of the control problem broken down from the top level into the logical
partitions.
than ever
5. Definition of the required function blocks.
PLC users can use
6. Definition of scan cycle time requirements for the different parts of the application. programming
7. Configuration of the system by defining resources, linking programs with physi-

cal inputs and outputs and assigning programs and function blocks to tasks.
IEC 61131-3 provides the right environment to support these steps. Consider this ex-
ample of a fermentation process and its control system. Shown below is a drawing of
the whole system (Figure 1). It should be looked at it as an operational system.
The fermentation process consists of a large vessel, which can be filled (feed valve)
6
with the liquid, can be heated with the heater band (cooling via convection), can be Structuring with IEC
stirred via the motor, and where acid and alkali fluid can be added into the vessel.
61131-3: 7 steps to
success
After the process time we use the harvest valve to get to the result.
PLC
To create a control program for this example, go through all of the seven steps as
defined above: Micro PLCs versus
Programmable Relays
1. Identification of the external interfaces to the control system PLCs power industrial data
integration
• Feedback from the temperature sensor
• Feedback from the pH sensor PLC software benefits for
• Feedback from the valve positions
• Feedback from the motor (speed) Should I use an edge
• Output to the valves
• Output to the motor The PLC remains stronger
than ever
• Output to the heater band.
PLC users can use
2. Definition of the main signals exchanged between the control system and the
programming
rest of the plant.
In this example, there is no coupling to the rest of the plant, which is not very realis-
tic. For instance, one could need a link to the vessel from which the liquids are pored,
and a link to a system for harvesting, like a transportation system for vessels or bottles.
There also could be couplings to an enterprise resource planning (ERP) system.
3. Definition of all operator interactions, overrides and supervisory data.

For the operator we define a ‘Start’, ‘Stop’ and ‘Duration’ buttons as input to the
system.
7
4. Analysis of the control problem broken down from the top level into the log- Structuring with IEC
ical partitions
61131-3: 7 steps to
success
There are five main functions to this process:
PLC
1. Main sequence, for example, top-level process steps – filling, heating, agitating,
fermenting, harvesting, cleaning; Micro PLCs versus
Programmable Relays
2. Valve control, such as operating valves used to fill and empty the vessel; PLCs power industrial data
integration
3. Temperature control for monitoring the temperature of the vessel; modulating PLC software benefits for
the heater;
4. Agitator control for the agitator motor activated as demanded by the main pro-
cess sequence; The PLC remains stronger
than ever
5. pH control for monitoring the acidity of the fermentation contents, adding acid- PLC users can use
ic or alkali reagents as required.
programming
5. Definition of the required function blocks

Using the definitions above and adding the (high level) function blocks to it, we can
represent these in the programming language the function block diagram. The over-
view of the fermentation control program could look like this (Figure 2).
The function block main sequence is linked to the operator inputs. It is supported by
the other blocks for control, which are linked to the relevant inputs and outputs. These
additional blocks could be blocks that are delivered by your suppliers, like the tem-
8
perature control block, Structuring with IEC

using a PID control loop.
61131-3: 7 steps to
success
Alternatively, these blocks
can be created by your- CLICK PLUS PLC vs CLICK
PLC
self. For instance, this is
the case with the bloc Micro PLCs versus
Programmable Relays
main sequence. Looking
closer to this block, we PLCs power industrial data
integration
could structure its se-
quence with SFC as fol- PLC software benefits for
lows (Figure 3).
Figure 3: Sequential function charts (SFC) provides
a means for partitioning a programmable
SFC provides a means for partitioning a
controller program into a set of steps and The PLC remains stronger
programmable controller program into a set
transitions interconnected by directed links. than ever
of steps and transitions interconnected by Courtesy: PLCopen
directed links. Associated with each step is a PLC users can use
set of actions, and with each transition is associated a transition condition.
programming
We start at the top with the Initialization: since we do not know the status of the
system when we first switch it on, we must check the position of the valves, etc. Then
we start filling till the right level has been reached. The next phase is the heating till
the fermentation process starts. When it does, we move to the next phase: the actual
fermentation process control part. After completion, we harvest, and after that clean,
and we are ready to restart at the top.
This decomposition gives everybody involved a clear overview which sequences

9
are involved, and further modularization into the function blocks which can be pro- Structuring with IEC
grammed in any of the four languages.
61131-3: 7 steps to
success
The programming work now to be done is at the level of the action blocks. Those CLICK PLUS PLC vs CLICK
PLC
could be divided between different people, with different backgrounds. For this, IEC
defined 2 graphical and 2 textual programming languages, which are Instruction List, Micro PLCs versus
Programmable Relays
Structured Text, Ladder Diagram and Function Block Diagram, to best suit the needs
and the problem at hand. Also, further decomposition of the action blocks can be PLCs power industrial data
integration
done via SFC, if needed.
6. Definition of scan cycle time requirements for the different parts of the ap-
plication Should I use an edge
In this example we have in principle only one cycle, which we can run in a continuous
mode. Alternatively, we could have it run on a time basis, for instance every 20 msec. The PLC remains stronger
than ever
The remaining time can be used for additional sequences, for instance checking or
controlling the transportation / bottling system during harvesting or checking all kind PLC users can use
of boundary and/or error conditions.
programming
7. Configuration of the system by defining resources, linking programs with phys-

ical inputs and outputs, and assigning programs and function blocks to tasks
This phase is dedicated to the system involved. It includes the physical mapping of
the symbols to I/O addresses. By using symbolic representation, one creates a far
better hardware independence. This is especially valid for the creation of the func-
tion blocks, which should be hardware independent. By identifying clearly where
the physical mapping is done, rewiring in the filed is a lot easier to accomplish. For
instance, exchanging the wiring of two digital inputs means that within the physical
10
mapping one has to change only two lines, the rest of the program is still valid and Structuring with IEC
need no changes.
61131-3: 7 steps to
success
The resources here are mapped, meaning which part runs on which processor in the CLICK PLUS PLC vs CLICK
PLC
system. IEC 61131-3 supports multiprocessing environments, although most of the
actual systems still use one processor for the programs. Micro PLCs versus
Programmable Relays
The user also has to map the tasks to the scan cycles and events, as defined in step PLCs power industrial data
integration
6. In this way, one can have multiple programs in one system, for instance the fer-
mentation process as described here, supported by overall checks and control of the PLC software benefits for
supporting environments, like bottling or the levels in the supplying chain upfront.
The IEC 61131-3 programming standard provides a powerful tool for multiple levels
of users and usage. Using an SFC at a high level gives an excellent overview on the The PLC remains stronger
than ever
system under development, resulting in higher readability and transparency. It pro-
vides guidance to the modularization of the control problem at hand. In addition, it PLC users can use
provides a basis for separating the different development tasks and focuses attention
programming
towards creating re-usable software code at the level of the actual coding.
Eelco van der Wal

Eelco van der Wal, managing director, PLCopen, a CFE Media content partner.
11
CLICK PLUS PLC vs CLICK PLC
Structuring with IEC 61131-

3: 7 steps to success
CLICK PLUS PLC vs

CLICK PLC
Micro PLCs versus
Programmable Relays

integration



than ever
PLC users can use

programming
CLICK PLUS PLC vs CLICK PLC

The Click PLUS PLC has added a great value to the CLICK PLC line.
This video details some of the features and highlights that makes
the CLICK PLUS and CLICK PLC similar and also what makes CLICK
PLUS the “New Best VALUE in PLCs” from a PLC.
12
Micro PLCs versus Micro PLCs have greatly improved their price/
performance ratio over the last few years, making
them the right choice for more applications as
Programmable compared to programmable relays.
Relays T he line between programmable relays and micro

PLCs has moved to a much lower price point over
the last few years, making a micro PLC a better option
for controlling many small to medium size machines.
Micro PLCs are no more expensive nor difficult to use
than programmable relays in these applications, and the
required training is about the same, as is the program-
ming effort.
Programmable relays shine in situations where the ap-

plication is simple and fixed, with little or no changes
required, and where a limited local operator interface is
required. In these applications, a programmable relay will
be lower cost than a micro PLC and a separate operator
interface. Although control functions and features are lim-
ited, they include debouncing an input signal, time de-
lays before turning on an output, pulse duration outputs,
and others.
BY BILL DEHNER
Programmable relays used to provide a significant ad-
Technical Marketer Engineer, at
vantage in applications with just four to eight inputs and
AutomationDirect
Micro PLCs versus Programmable Relays
four to eight outputs, but this has changed as micro PLCs have declined in price and Structuring with IEC 61131-
increased in capabilities. In the past, many users would only consider a step up to a mi-
cro PLC if more complex logic was required, but this assumption is no longer correct. CLICK PLUS PLC vs CLICK
PLC
Micro PLCs, such as the CLICK from AutomationDirect have many advantages for use Micro PLCs versus
in automated machines and processes, which will be briefly discussed in this white pa- Programmable Relays
per. A short definition of a micro PLCs and programmable relays will also be provided. PLCs power industrial data
The bottom line: a micro PLC should be used in all but the simplest applications due integration
to a host of advantages as compared to a programmable relay. PLC software benefits for

What is a Micro PLC? Should I use an edge

The use of newer technology in micro PLCs has created a very compact, less expensive
PLC with the price/performance ratio required to move into what was once exclusively The PLC remains stronger
than ever
programmable relay territory. Several of the advantages of a micro PLC over a pro-
grammable relay are listed in Table 1. PLC users can use
programming
TABLE 1: Advantages of a Micro PLC
• Expandability
• Better price/performance ratio
• More communication options
• Easy to add full-featured operator interface
• Easier to create advanced programs
AutomationDirect’s CLICK PLC will be used to illustrate these advantages, although

some other micro PLCs share some of the same attributes (Figure 1).
14
The CLICK comes in a variety of models with Structuring with IEC 61131-
built-in I/O and removable terminal blocks for
easy wiring. Additional modules can be added to CLICK PLUS PLC vs CLICK
PLC
expand I/O if needed. The CLICK CPUs include
different combinations of discrete and analog Micro PLCs versus
inputs and discrete and analog outputs. It can Programmable Relays
be expanded to a total of 142 discrete I/O or 54 PLCs power industrial data
analog channels (Figure 2). The CLICK starts at a integration
cost of $69, a price point common for many pro- PLC software benefits for
grammable relays, while delivering much more industrial manufacturers
functionality and flexibility. Should I use an edge
The CLICK includes various communication op- The PLC remains stronger
tions and models with a real-time clock. Built- than ever
in communication can include a 10/100 Mbps PLC users can use
multipurpose Ethernet port for networking and cloud services without
Figure 1: This CLICK Micro PLC has programming
control. This port can be used to program the PLC, built-in I/O and communication
network it or control Ethernet-enabled devices—using options, making it suitable for use in a
wide variety of applications.
Modbus TCP.
Other communication options in micro PLCs include RS-232 communications ports for
programming, or for configuring MODBUS RTU or ASCII protocols. RS-485 communi-
cation is also available.
These communication options enable easy connection to a wide variety of operator in-
terface terminals (OITs), such as AutomationDirect’s C-more or C-more Micro. Whether
15
serial or Ethernet is used, Structuring with IEC 61131-

the connection is simple,
and can quickly provide CLICK PLUS PLC vs CLICK
PLC
extensive text and graph-
ical display features on a Micro PLCs versus
touch screen much larger Programmable Relays
than found on programma- PLCs power industrial data
ble relays. The CLICK CPU integration
can also power the C-more Figure 2: The CLICK Micro PLC can PLC software benefits for
Micro from the serial connection alleviating the need expand up to a total of 142 discrete industrial manufacturers
I/O or 54 analog channels using 24
for additional power wiring. Should I use an edge
different digital and analog modules,
including AC, DC, relay, thermocouple
The CLICK micro PLC includes only 21 instructions, and RTD for more complex The PLC remains stronger
applications. than ever
suitable for most small to medium size applications,
which makes it easy to program. The limited instruc- PLC users can use
tion set reduces training needs, and the PC-based programming software is free. cloud services without
programming
A micro PLC provides a more scalable solution than a programmable relay, provid-
ing room for future expansion. As a machine is updated or improved, more advanced
programming and additional I/O can be added to a micro PLC, while the limits of
programmable relays are often quickly reached. Both a micro PLC and a programmable
relay can often provide a control solution at reasonable cost, but the future benefits of
using a PLC should be considered.
What is a Programmable Relay?

A programmable relay is a small device that includes several inputs and outputs pro-
16
viding relay, timer and counter functions in a single unit. Most programmable relays Structuring with IEC 61131-
include a small amount of I/O, but some include over 20 discrete inputs and outputs,
as well as up to eight analog inputs and eight analog outputs. CLICK PLUS PLC vs CLICK
PLC
Programmable relays often include a built-in LCD display, such as 6 lines and 20 char- Micro PLCs versus
acters per line, to display the program, variables and configuration. Also included Programmable Relays
are function keys and buttons on the front face of the relay for navigation; entering PLCs power industrial data
and editing the program and parameters; and starting, stopping and configuring the integration
device. PLC software benefits for

These built-in displays have distinct limitations. Knowledge of the actual application Should I use an edge
and the variables, using a cheat sheet, are often required as the display provides little controller, PLC, or PAC?
information. The PLC remains stronger
than ever
Although programmable relays provide simple installation, minimal wiring and us- PLC users can use
er-friendly programming—micro PLCs can make the same claim. Either option works cloud services without
programming
well in small to medium size automation applications. Both are small controllers that
can automate functions such as simple sequences based on time or events, time-de-
lays, counters, and relay logic or relay replacement.
Training Requirements
A common misconception with programmable relays is that no training is required to
learn how to program it, but this is simply not true for all but the most basic applica-
tions. Once more than a few I/O points are needed, the coding complexity for a pro-
grammable relay is very similar to a micro PLC when using PC-based programming
software. And the option of coding a programmable relay from its built-in display is
17
simply not practical for all but the most basic appli- Structuring with IEC 61131-
cations.
PLC
When programmable relays start to move into
micro PLC territory in terms of I/O points and Micro PLCs versus
functionality, complexity increases along with cost. Programmable Relays
Training requirements for programming and imple- PLCs power industrial data
mentation become similar, with no advantage to integration
either platform. PLC software benefits for

A review of three of the more popular high-end Should I use an edge
programmable relays found two of the manuals to be Figure 3: This Fuji Timer Relay controller, PLC, or PAC?
is a cost-effective solution for
about 200 to 250 pages in length, with the third at over The PLC remains stronger
applications requiring only a
550 pages. This third programmable relay required almost than ever
single timer output function.
200 more pages for a user manual as well, for a total of PLC users can use
almost 750 pages. Each of these three programmable relays cost more than a CLICK cloud services without
programming
micro PLC, and did not include the features, functions and capabilities listed in Table 1.
Of course, the CLICK micro PLC has a User Manual as well, and it’s just under 300
pages. This manual includes a step-by-step quick start guide, all hardware specifica-
tions for the controller and expansion discrete and analog, installation and wiring,
communication, maintenance and troubleshooting information. And, if you need help
selecting CLICK PLC components, there is an AutomationDirect configuration tool to
configure and order the hardware.
A very simple programmable relay, specifically a timer relay, with an octal base, dip
18
switches and a potentiometer to select function modes and time, includes only a Structuring with IEC 61131-
4-page user manual, so it is easy to use. If an application requires only a single,
heavy-duty SPDT electro-mechanical output relay with on-delay, off-delay or interval CLICK PLUS PLC vs CLICK
PLC
output, this type device is a good choice (Figure 3).
Micro PLCs versus
With either a micro PLC and all but the simplest programmable relay, some training will Programmable Relays
be required, and users will have to read the manual. In the case of the CLICK PLC, it is PLCs power industrial data
likely that the 24-page quick-start guide will get most users up and running quickly. For integration
those who need more training or have questions, there is free a 30-day training cer- PLC software benefits for
tificate included with each CLICK CPU purchased, as well as award-winning technical industrial manufacturers
support available from AutomationDirect. Should I use an edge
On-Board Programming The PLC remains stronger

than ever
Most programmable relays promote the fact that the device can be programmed using
the built-in front panel display of the relay, so there’s no need for PC-based program- PLC users can use
ming software. While this is technically true, it is not simple to enter a program, param- cloud services without
programming
eters and configuration using a display and buttons not much bigger than a pack of
matches.
It is still necessary to enter contacts and coils, link them together and insert rungs. If
possible with the selected programmable relay, comments should be added to ease
understanding of the control logic. Some programmable relays even use function
blocks that are even more difficult to see and use.
Viewing ladder logic or function block programming on a small LCD display on a pro-
grammable relay mounted to control panel in an enclosure located at knee level is not
19
practical for most. Interpreting the screen symbols, with no descriptors, requires train- Structuring with IEC 61131-
ing or reading the manual. Add to that some complexity in the control logic, and the
capability of coding a programmable relay via its built-in display disappears quickly in CLICK PLUS PLC vs CLICK
PLC
most applications.
Micro PLCs versus
In many cases, understanding or remembering what buttons to press to access or edit Programmable Relays
the program or modify parameters can require many steps. Users must typically po- PLCs power industrial data
sition a curser using navigation keys to access a menu; hold a program, parameter or integration
shift key to access a function or parameter to edit the value; accept it; exit edit mode; PLC software benefits for
and return to run mode. These functions and capabilities, while built-in to a program- industrial manufacturers
mable relay’s display, are available with a much better user experience using PC-based Should I use an edge
programming software. controller, PLC, or PAC?

than ever
Programming Details
Both programmable relays and micro PLCs can be programmed using PC-based soft- PLC users can use
ware. Depending on the controller, the programming software will be either available cloud services without
programming
via a free download, or can be purchased for a low price. With either device, it will take
time to be efficient with the programming software.
Both PLC and programmable relay software provides the tools to program the hard-
ware to meet the application requirements, and both include extensive online pro-
gramming help files. In the CLICK’s case, the PLC programming software can be down-
loaded for free, or purchased on CD. Users will find the CLICK programming software
simple, with a practical instruction set available to get the program created and run-
ning quickly, and the help files are extensive.
20
With the basic instructions and documentation available with the CLICK micro PLCs, Structuring with IEC 61131-
training is not needed, but it is available. Once the PLC is installed and wired, a quick
start guide can lead the user through the nine steps required to create a program CLICK PLUS PLC vs CLICK
PLC
shown in Table 2.
Micro PLCs versus
TABLE 2: Nine Steps to Create a Micro PLC Program Programmable Relays
1. Download and install the free programming software on a PC integration
2. Launch the programming software PLC software benefits for

3. Create a project (program) industrial manufacturers
4. Compile and save the project Should I use an edge
5. Apply power to the PLC controller, PLC, or PAC?
6. Establish PC to PLC communication The PLC remains stronger
7. Download the project to the PLC than ever
8. Place PLC in run mode PLC users can use
9. Test project using PC software’s data view monitor cloud services without
programming
In this CLICK example, following the instructions in about 24-pages of a welllaid-out

chapter in the manual, it is possible to quickly learn how to create, compile and trans-
fer a ladder logic project to a CLICK PLC, and then run and test the project. While the
quick start shows how to add relay contacts and coils to ladder logic to turn on an out-
put, there are additional instructions available for the CLICK PLC. Details about other
instructions are available in the programming software’s online help topics.
Don’t Forget the Documentation

With a programmable relay, a program can also be entered with PC programming
21
software and downloaded to the device. Structuring with IEC 61131-

As discussed, the programmable relay’s
basic, built-in operator interface could CLICK PLUS PLC vs CLICK
PLC
also be used for programming. But while
programming using the front panel seems Micro PLCs versus
convenient, it can provide a quick path to Programmable Relays
confusion. PLCs power industrial data
integration
It is difficult to follow programming using PLC software benefits for

the small display built-in. It is also near- industrial manufacturers
ly impossible to document the program Should I use an edge
without using the PC. The next time the controller, PLC, or PAC?
programmable relay program needs edit- The PLC remains stronger
Figure 4: A CLICK micro PLC than ever
ing, it can be difficult to follow existing programming unless
is often a better choice than a
it is saved to a PC and accessed with the appropriate pro- programmable relay for all but PLC users can use
gramming software, just as with a micro PLC. the simplest and most basic cloud services without
applications. programming
On the other hand, the CLICK micro PLC has sufficient mem-
ory for the ladder program and on-board documentation. Using this feature, program
software and associated documentation including comments, tag names, rung descrip-
tions, etc. can be stored on-board the CLICK micro PLC. This eliminates the need to
maintain the documentation externally, especially useful when the program is lost, or it
is being edited using a different PC in the future.
Conclusion
A micro PLC is a better solution than a programmable relay for simple to moderate
22
machine control applications. A programmable relay should be chosen when the appli- Structuring with IEC 61131-
cation is very simple and will never be changed, and when the local operator interface
display is sufficient and required. CLICK PLUS PLC vs CLICK
PLC
Due to recent technical developments, micro PLCs are no longer just relay and tim- Micro PLCs versus
er replacers, but can replace programmable relays in many applications. It should be Programmable Relays
clear from the examples given above that it is incorrect to think that a micro PLC solu- PLCs power industrial data
tion is more expensive than a programmable relay. In fact, a CLICK micro PLC will cost integration
less up front in all but the simplest applications. It is also not true that the PLC will take PLC software benefits for
more time to program and will require more training (Figure 4). industrial manufacturers

For those who think a micro PLC would be overkill and might choose a programma- controller, PLC, or PAC?
ble relay instead, AutomationDirect suggests a close look at their CLICK micro PLC. The PLC remains stronger
It’s the better and less expensive solution in many applications, and it’s well suited for than ever
future expansion. PLC users can use
programming
23
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PLCs power industrial
data integration Structuring with IEC 61131-

Programmable logic controllers (PLCs) have recently gained capabilities PLC
formerly possible only with PCs, expanding their role to support seamless
Micro PLCs versus
data integration with the enterprise. Programmable Relays

N ot long ago, the roles of industrial automation devices and systems were a lit-
tle more straightforward. Most field devices and sensors were relatively “dumb”
and were directly connected to controllers, which may have interacted with operator
data integration
displays, and in rare cases some data may have flowed up to higher level enterprise
systems. Today’s smart sensors, clever controllers, and more capable communications Should I use an edge
have improved upon this scenario, and end users are looking for the best ways to en-
able the enterprise host systems to access valuable field-level data. The PLC remains stronger
than ever
The operational technology (OT) domain of sensors, programmable logic controllers PLC users can use
(PLCs), and human-machine interfaces (HMIs) is converging with the information tech- programming
nology (IT) world of PC servers and cloud connectivity. These technologies are more
intelligent than ever with a lot of overlapping functionality. This means users have more
options for building or upgrading an industrial automation system to deliver integrat-
ed data. Applications where OT data is accessed with IT methods are often referred to
as Internet of Things (IoT) implementations.
Some of today’s PLCs are speeding end users on their journey to extract data from
manufacturing systems and transporting it to enterprise systems so users can make
informative decisions on how to optimize operations. IT-friendly additions are making
OT-centric PLC platforms more effective for optimizing operations.
25
PLCs power industrial data integration

Yesterday’s PLC data 3: 7 steps to success
flow challenges…
Gathering field data, let alone PLC
connecting to some higher-lev-
Micro PLCs versus
el host system, historically has Programmable Relays
involved several types of chal-
lenges. Hardwired sensors were
data integration
easiest to connect to a PLC, but
publishing PLC information up to PLC software benefits for
on-site or cloud-based systems
required careful curation of data Should I use an edge
structures, along with configur-
ing network and communication The PLC remains stronger
than ever
protocols. PLCs didn’t support all
the industrial protocols required PLC users can use
to talk with more intelligent field programming
devices, and they had limitations
for connecting with host systems.
Navigating the architectural
hierarchy from the control level,
through operations, up to the en-
Figure 1: Sending valuable plant floor
terprise systems and the cloud was a thorny problem
data up to higher level operations,
(Figure 1). enterprise, and remote cloud systems
has traditionally entailed troublesome
configuration for many layers of
Users needed to generate custom configurations of
hardware, software, and networking.
code to select, arrange and manage data. Then they Courtesy: AutomationDirect
26
had to take additional steps to handle extended information like scaling, engineering Structuring with IEC 61131-
units and tag descriptions. A lot of parts and effort might be involved: PLCs, gateways,
PCs, software packages, network configuration and custom code. CLICK PLUS PLC vs CLICK
PLC
Even when data connectivity could be patched together, it was often at the expense of Micro PLCs versus
Programmable Relays
security. Traditionally, PLCs have not included strong cybersecurity provisions, especial-
ly for internet-connected systems. PLCs power industrial
data integration
…are solved by today’s PLC tech PLC software benefits for
Fortunately, some modern PLCs include all the elements needed to overcome these
challenges, eliminating complexity from the task of getting data from the shop floor up Should I use an edge
to the cloud and enterprise.
than ever
PLCs have been an established and reliable platform for edge automation tasks. In-
stead of creating a new category of device only tasked with data communication du- PLC users can use
ties, some vendors realized next-generation OT-based PLCs could be enhanced with cloud services without
programming
the necessary IT-associated tech to effectively integrate data (Figure 2).
For best results, all data integration elements need to reside natively in the PLC prod-
uct, providing an off-the-shelf experience for users. End users, especially in the IT field,
also are looking for open source-based technologies because they are already familiar
with this approach, as opposed to the specialized environments common to OT prod-
ucts.
A PLC bundling data integration protocols bridgesOT and IT systems and can create
many ways to connect new and legacy factory floor equipment to today’s enterprise
27


PLC
Micro PLCs versus

Programmable Relays

data integration


than ever
PLC users can use

programming
systems. Popular serial and Ethernet OT protocols in- Figure 2: Next-generation PLCs, like
the AutomationDirect BRX Series,
clude ASCII, Modbus RTI K-Seq, Modbus TCP and Eth- are built from the ground up with OT
erNet/IP (ODVA). Essential IT protocols include SNTP and IT communication protocols, and
the necessary security features, for
DNS, MQTT, SMTP, SSL and web services.
enabling seamless data integration.
With the free programming software,
Multiple PLC integration options users can configure the BRX (with
or without classic I/O) to also
PLCs can enable popular data integration options de- act as a data gateway. Courtesy:
pending on application needs. AutomationDirect
28
Store data in the PLC and forward via FTP Structuring with IEC 61131-
Today’s PLCs have enough memory to log data locally over a period of hours, days, CLICK PLUS PLC vs CLICK
PLC
or weeks—and then forward it to a network- or cloud-connected computer using file
transfer protocol (FTP). This form of storing and forwarding data can be effective for Micro PLCs versus
Programmable Relays
bulk transactions, which do not need to be near-real-time, however, it will require the
user to configure the PLC for aggregating the data and the host system for parsing the PLCs power industrial
data. data integration
Web server industrial manufacturers

Sometimes it is only necessary for a PLC to expose limited data for read-only, near controller, PLC, or PAC?
real-time remote viewing by users. In this case, some PLCs include built-in web servers, The PLC remains stronger
empowering users to develop HTML5 displays of data and information viewable us- than ever
ing browsers. No other additional software or licensing is required. A downside to this PLC users can use
basic approach is the need for clients to be connected on the same network – or via a cloud services without
programming
firewall and routing – with the proper access privileges.
MQTT over TLS
The messaging queuing telemetry transport (MQTT) protocol has emerged as the
common standard for PLC-to-cloud communications, for several reasons. While it of-
fers two-way communications, the PLC in the field initiates conversations as outbound
messages to a centralized broker, which can be on premises or more commonly in the
cloud. This helps avoid firewall and IT management issues. Although MQTT can be
implemented without security, best practice is to perform communications using the
29
standard transport layer security (TLS) networking protocol, and to use other security Structuring with IEC 61131-
features provided within MQTT.
PLC
MQTT communications are processed quickly, but are resilient enough to withstand
the kinds of network outages that can occur for industrial and edge-located installa- Micro PLCs versus
Programmable Relays
tions. Users can access the broker data with enterprise and/or mobile clients, or they
can implement cloud computing services to connect with PLC-sourced MQTT data PLCs power industrial
directly. data integration
REST API industrial manufacturers

The previous three methods require users to manage and configure the source data at controller, PLC, or PAC?
the PLC. However, if a PLC offers a representation state transfer (REST) application pro- The PLC remains stronger
gramming interface (API), then external clients can initiate communications and access than ever
data residing in PLC memory with a standard request (Figure 3). PLC users can use
programming
This powerful ability makes it easier for users to change polled data tags in the future,
as no modifications are needed in the PLC. The client sends a request to the PLC, and
the PLC gathers the necessary data from its memory and replies with the data assem-
bled into an easy to read and parse JavaScript Object Notation (JSON) format. Mes-
saging occurs via HTTP requests from clients, using traditional and typically open IT
ports, like port 80. However, as with the web server option, external clients must be on
the same network or permitted through any firewalls.
Security must be built-in

One natural consequence of improved PLC data connectivity options is greater expo-
30


PLC
Micro PLCs versus

Programmable Relays

data integration


than ever
PLC users can use

programming
sure of the PLC to bad actors who could access Figure 3: AutomationDirect BRX Series PLCs
potentially valuable information. Therefore, new include multiple data connectivity options.
A REST API enables external clients, such
PLCs must include built-in security features, ex- as Node-RED operating on a computing
tending far beyond what was offered in previous service, to initiate requests to access data
residing in PLC memory, so long as proper
generations. Users should look for:
31
security credentials are presented. Courtesy:
AutomationDirect
• PLCs that are by default (right out of the box) not open to requests from the out- Structuring with IEC 61131-
side world
PLC
• The ability to store username and password credentials on-board (managed by OT
personnel using programming software) Micro PLCs versus
Programmable Relays
• Support for IP whitelisting to control which external clients are allowed to commu- PLCs power industrial
nicate with the PLC data integration
• Secure communications over TLS when possible. industrial manufacturers

With the right tools and security, users are afforded a world of options for creating safe controller, PLC, or PAC?
PLC-based data connectivity. The PLC remains stronger
than ever
Applications for modern PLCs PLC users can use

Many IoT clients are remote monitoring applications needing to receive certain items cloud services without
programming
of data. Sometimes developers will configure programming tools that are IT-centric
methods for preprocessing, formatting, transforming, and configuring data for con-
sumption by other applications.
Designers can build new systems using a modern PLC able to support these types of
connections, or they can implement such a PLC on top of an existing system to add IoT
capability. Data becomes easily available using one or more of the methods described
here, so developers can focus their efforts on the host applications.
For example, a solutions provider developed a cloud-based IoT application that can
32
access many operational sites, such as pump houses, using MQTT. Before PLCs were Structuring with IEC 61131-
available to support MQTT and other methods, it was necessary for developers to add
dedicated communication gateways. CLICK PLUS PLC vs CLICK
PLC
Micro PLCs versus

PLCs are the future of OT data connectivity Programmable Relays
Whereas yesterday’s industrial automation products were often very specialized and
somewhat limited in terms of data handling, the processing power incorporated in to- PLCs power industrial
data integration
day’s OT digital devices imbues them with greater capabilities. These new capabilities
are addressing end user needs for obtaining timely field data to support IoT and ana- PLC software benefits for
lytical initiatives at the enterprise level.
OT-based PLC technology is already well-proven in the field. The addition of IT-friend-
ly protocols and security features to PLCs makes them ideal as edge devices for ac- The PLC remains stronger
than ever
cessing raw field data using industrial protocols, processing it into information, and
securely publishing or transmitting it to any industrial IoT client or external computing PLC users can use
platform. cloud services without
programming
Damon Purvis
Damon Purvis is the PLC product manager at AutomationDirect.
33
industrial manufacturers Structuring with IEC 61131-

Software-based programmable logic controllers (PLC) present numerous PLC
advantages over traditional hardware products and the addition of software
Micro PLCs versus
systems enables greater productivity, detailed reporting for optimization and Programmable Relays
overall system flexibility. PLCs power industrial data
integration
S oftware-based programmable logic controllers (PLC) present numerous advantag-

es over traditional hardware products. As with many applications in the industrial
sector today, the addition of software systems enables greater productivity, detailed
PLC software
benefits for industrial
manufacturers
reporting for optimization and overall system flexibility.
Many of these capabilities go directly against the traditional, physical production line
concepts of manufacturing. Technology is bringing production into a new era. Like- than ever
wise, the advantages of using a software-based PLC are significant. Networking is
PLC users can use
crucial for any organization, and in any given company, there may be several different cloud services without
types of networking systems. programming
One benefit of software-based PLCs is they facilitate simple integration of networking

systems for easy communication. This opens the door for numerous productivity ben-
efits and provides upper management with a simple platform where operations can be
monitored.
Another major benefit of software-based PLCs is they provide safety and security ad-
vantages over hardware appliances. In traditional models, information is held within
the system, and is vulnerable to unauthorized access and other risks. PLC software only
34
PLC software benefits for industrial manufacturers
gives information to those who are authorized and comes with more advanced security Structuring with IEC 61131-
features. Software-based PLCs can also help cut production costs.
PLC
Input and output devices connected to the PC system use Ethernet cables. These
are more cost effective than traditional PLC connections which had large connec- Micro PLCs versus
Programmable Relays
tions and many applications. Ethernet cables are faster and increase the speed of the
workflow. PLCs power industrial data
integration
There are many advantages of software-based PLCs, but the networking, safety, and PLC software
cost benefits are some of the biggest and most immediate ones. Software-based PLCs benefits for industrial
manufacturers
bring productivity to just about any operation.
This article originally appeared on the Robotics Online Blog. Robotic Industries Asso-
ciation (RIA) is a part of the Association for Advancing Automation (A3). A3 is a CFE The PLC remains stronger
than ever
Media content partner.
PLC users can use
programming
35
Should I use an Industrial automation end users are finding
edge control technologies excel at familiar
programmable logic controller (PLC) and
edge controller, programmable automation controller (PAC)
applications while delivering future-proof
PLC, or PAC? computing and communication options.
E dge controllers can provide advantages in many ap-

plications where traditional industrial controllers have
been used. For commercial and industrial computing
products, software and hardware development progress
proceeds in tandem, with the lead alternating. Some-
times the software complexity and features increase in a
way that bumps into processing limitations; then there
are times when hardware advances unleash newfound
capacity for more sophisticated software.
It is easy to look at today’s traditional operations technol-

ogy (OT) industrial controller options, represented most
often by traditional programmable logic controllers (PLCs)
and process automation controllers (PACs), and see them
as mature technologies with capable software and fast
hardware. The challenge is identifying what comes next.
A few industry trends are pointing the way. Modern

consumer and commercial computing experiences are
Should I use an edge controller, PLC, or PAC?


PLC
Micro PLCs versus

Programmable Relays

integration


controller, PLC, or
PAC?
than ever
PLC users can use

programming
ripe for merging into industrial products. Figure 1: Edge controllers, such as those offered
Internet of Things (IoT) devices are becom- by Emerson, combine deterministic control like a
PLC or PAC, and independent general-purpose
ing commonplace and many are looking at processing like a PC. Courtesy: Emerson
incorporating Industrial IoT (IIoT) devices
into automation systems. Digital transformation requires connecting with many
data sources, collecting and storing the data, visualizing and analyzing it, enabling
optimized operations.
37
The journey to realize value in these trends calls for something new; an edge con- Structuring with IEC 61131-
troller that is more than a PLC or a PAC. Edge controllers are making it possible for
implementation of robust automation systems to continue as they always have and CLICK PLUS PLC vs CLICK
PLC
seamlessly add the latest communication and application development options.
Micro PLCs versus
Programmable Relays
Edge controllers can upgrade existing systems, create new designs, improve produc-
tivity, address skill gaps and enhance security. PLCs power industrial data
integration
Edge controller hardware and the software PLC software benefits for
Casual observers and implementers of industrial technology can be excused for be-
lieving the industrial controller world has plateaued in processing power and physical Should I use an edge
footprint, looking at simple processor clock speed.
controller, PLC, or
PAC?
Cutting-edge commercial and industrial processors, however, have realized substan- The PLC remains stronger
than ever
tial processing performance gains due to multi-core designs and increasing num-
bers of processor cores in a device. At the same time, hardware-level virtualization PLC users can use
provides a convenient way to manage multiple cores and assign them to virtual ma- programming
chines (VMs).
PCs and servers used in conjunction with industrial controllers already benefit from this
improved computing performance coming from the fast-paced commercial world.
Deterministic industrial control systems, on the other hand, require high speed, re-
peatable and time-based processor execution. Unlike many commercial applications,
any industrial application of VMs and multi-core management must be free from jitter
or any other deviations from reliable timely operation.
38
Realizing equivalent perfor- Structuring with IEC 61131-

mance gains for industrial
applications, therefore, CLICK PLUS PLC vs CLICK
PLC
requires a new class of con-
troller, and the edge con- Micro PLCs versus
Programmable Relays
troller was born. (Figure 1).
These controllers feature PLCs power industrial data
integration
multiple cores managed
through carefully crafted PLC software benefits for
VMs. A real–time operating
system (RTOS) supports Should I use an edge
reliable, deterministic controller, PLC, or
PAC?
runtime control, similar
to a PLC or PAC. The real The PLC remains stronger
Figure 2: A bare metal virtualization hypervisor than ever
upgrade is the addition of a second on-board
design as used with Emerson edge controllers
general-purpose operating system (OS) run- delivers rock-solid deterministic control in PLC users can use
parallel with an independent general-purpose cloud services without
ning a variant of Linux.
OS. Courtesy: Emerson programming
The two OSs are independent at the hardware

level, but they are able to communicate with each other via OPC UA. The “open”
general-purpose OS can even be rebooted independently without affecting the de-
terministic runtime.
Combining a deterministic runtime with a general-purpose OS is a true advancement

that builds upon traditional control methods by enabling closely–integrated deter-
ministic computing and secure real-time data access technologies.
39

What makes edge controllers different? 3: 7 steps to success
Conventional PLCs and PACs will continue to be available for many years, although
today, many users find significant overlap in these product descriptions. The term PLC
PAC has been used to describe controllers with more advanced control strategies
Micro PLCs versus
and communication capabilities than a PLC, but in fact, many PLCs have been creep- Programmable Relays
ing into PAC capability territory.
integration
PLCs and PACs are good technologies developed during different eras. Edge control-
lers can update or replace PLCs and PACs to address current challenges. Edge control-
lers can offer advantages by implementing carefully–designed OSs for addressing OT
and IT needs for control, communications, and application development. Should I use an edge
controller, PLC, or
PAC?
As dedicated control devices with a specific functional scope, basic PLCs are often
“bare metal” designs or use an extremely limited and proprietary OS. PACs gained The PLC remains stronger
than ever
more advanced communication and functional services, while preserving a deter-
ministic runtime, through the use of an RTOS. For creating an edge controller, which PLC users can use
adds at least one general-purpose OS in addition to the deterministic runtime, de- programming
signers must address new considerations. Hosting all these functions in one OS puts
deterministic performance at risk. Incorporating a bare-metal virtualization hyper-
visor, however, enables deploying a rock-solid deterministic runtime securely and
independently in parallel with a general-purpose OS on the same platform (Figure 2).
This foundation is crucial.
PLCs used to be isolated or they communicated with slow and cumbersome serial
links. PACs included better industrial protocol implementation and Ethernet for im-
proved connectivity and interoperability. Edge controllers deliver these advantages,
40
but users must take Structuring with IEC 61131-

things to a whole new
level to perform in an CLICK PLUS PLC vs CLICK
PLC
increasingly IT-connect-
ed environment. Micro PLCs versus
Programmable Relays
They should incorpo- PLCs power industrial data

integration
rate a management
umbrella adding se- PLC software benefits for
curity and defenses
suitable for prevalent Should I use an edge
IT-like issues like net- controller, PLC, or
PAC?
work storms and denial
of service (DoS) attacks. In conjunction, IT-ori- Figure 3: Edge controllers implemented The PLC remains stronger
into automation systems provide a good than ever
ented protocols with built-in security such as
platform for those entering the workforce to
OPC UA, MQTT and secure sockets (HTTPS, apply coding skills and mobile computing PLC users can use
experiences. Courtesy: Emerson cloud services without
SSL, FTPS) can provide appropriately secure
programming
communications performance.
For application development, PLCs used mostly proprietary ladder logic and rela-
tively rudimentary tools. Taking on some concepts from the greater software industry,
PACs may offer a level of support for standard IEC–61131-3 programming languages,
custom user code blocks, and some basic capabilities for code reuse and object-ori-
ented design. A well–designed edge controller preserves the deterministic runtime,
and adds a computing environment for performing analytics, data aggregation, and
other advanced tasks.
41
The general-purpose OS allows application development in IT-oriented languages Structuring with IEC 61131-
like C and C++, Python, and Java. The most flexible architectures can allow OT per-
sonnel to focus on the deterministic system, IT personnel can work on the gener- CLICK PLUS PLC vs CLICK
PLC
al-purpose system, and the two groups can coordinate and crossover as needed or
desired in a clearly defined manner. Micro PLCs versus
Programmable Relays

How to move to edge control integration
When users only need a PLC/PAC feature set, they can still specify an edge controller
to fill that role. Standard IEC-61131-compliant programming methods can be used, PLC software benefits for
or even commercial languages like C. These users never need to access the gener-
al-purpose OS features if they choose not to. Should I use an edge
controller, PLC, or
PAC?
Those interested and perhaps more tech-savvy, however, should look for edge con-
trollers offering a native toolbox of IT-friendly features such as Linux OS, a Python The PLC remains stronger
than ever
interpreter, secure sockets, an embedded database and OPC Foundation OPC UA
support. Part of the reason IT-friendliness is so important is because much today’s PLC users can use
IIoT technology is built on Linux. Edge controllers provide an environment where us- programming
ers can safely and securely explore their while preserving deterministic operation.
With the deterministic and the general-purpose OS on one hardware platform, it

is easier to securely coordinate the two, compared to deploying separated devic-
es. The general-purpose OS has access to wider variety of information sources and
high-fidelity data from the deterministic system and IIoT devices. It also can perform
local analytics and advanced algorithm execution.
The results can be used to advise the deterministic system for optimal operation. In
42
addition, the gener- Structuring with IEC 61131-

al-purpose OS is ideal
for transforming raw CLICK PLUS PLC vs CLICK
PLC
Simple PLC control data into pre-pro-
Micro PLCs versus
...on STEROIDS! cessed information for
Programmable Relays
securely sharing with
Wi-Fi
higher level systems. PLCs power industrial data
(antenna sold
separately) integration
Bluetooth
(provisioning
only)
Controller us- PLC software benefits for
microSD
ability
Modern edge con- Should I use an edge
Stackable I/O Modules controller, PLC, or
USB
troller technology can
PAC?
Add up to 8 additional I/O
modules for applications with
larger I/O needs.
benefit those speci-
Ethernet The PLC remains stronger
fying, programming,
Built-in Option Module Slot
than ever
Serial
For custom stand-alone PLC I/O
configurations that exactly match and maintaining au-
PLC users can use
(RS-232 & your application (option module
sold separately).
tomation systems. At
RS-485)

design time, users programming
CPU unit starting at only $89 can select from prod-
We’ve taken our most practical, most popular PLC family and
supercharged it with features you wouldn’t expect from a simple uct families sized to
low-cost controller. Data logging, Wi-Fi connectability, MQTT
communication and increased security measures are just a few of meet the need from
the impressive features offered with the new CLICK PLUS PLC
series. With a starting at price of only $89.00 and free easy-peasy
programming software, CLICK PLUS PLCs are a “must have” for
Check out what puts the “PLUS” in
CLICK PLUS in this quick intro video:
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on a performance and
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using the same de-
Order Today, Ships Fast!
* See our Web site for details and restrictions. © Copyright 2020 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
terministic runtime
environments, the
43
2104-DesignWorld-CLICKPLUS-MAG.indd 1 3/5/2021 10:57:41 AM
same toolchains and configured with the same integrated development environment. Structuring with IEC 61131-
Users only need to learn one common environment and the code and configurations
can be reused. CLICK PLUS PLC vs CLICK
PLC
Another consideration is how end user demographics are changing. Experienced Micro PLCs versus
Programmable Relays
users already in the workforce are familiar with PLC and PACs. Their depth of experi-
ence affords them a more instinctive approach to programming, tuning, and trouble- PLCs power industrial data
integration
shooting based on the products which have used for years.
The newest software users entering the workforce, however, have grown up in the
smartphone age. They are used to modern programming languages and working in Should I use an edge
a developer kit environment rather than developing everything from scratch. In fact, controller, PLC, or
PAC?
they are probably most comfortable assembling code elements from a library or re-
pository to create a solution (Figure 3). The PLC remains stronger
than ever
Controllers fill the skills gap PLC users can use

The latest edge control automation platforms address the skills gaps in two ways. The programming
first is younger workers will be more comfortable and perform better in a development
environment that uses tools and languages familiar from their schooling or training.
The second is edge control capabilities are a good way to create advisory algorithms
to assist newer teams with operating and maintaining systems. Companies can rely on
a smaller set of experts and improve their productivity by leveraging the expertise in
the form of analytics and advising algorithms to empower the rest of the team.
Edge controller cybersecurity

Edge controllers, with their inherent connectivity and analytic capabilities, may raise
44
security concerns for traditional controls developers. Developers accustomed to Structuring with IEC 61131-
air-gapped networks as a standard security strategy may not be comfortable dealing
with more open networks. Many older automation platforms also were developed be- CLICK PLUS PLC vs CLICK
PLC
fore cybersecurity was considered a priority, and when security was addressed, it was
more of an add–on afterthought than a built-in feature. Micro PLCs versus
Programmable Relays
For edge controllers and the most modern PACs, on the other hand, security-by-de- PLCs power industrial data
integration
sign is a fundamental requirement. Suppliers of edge controller and PAC hardware
and software products should be able to: PLC software benefits for
• Validate the supply chain Should I use an edge

controller, PLC, or
PAC?
• Build their devices using trusted components and suppliers
than ever
• Incorporate hardware-based security technologies, such as trusted platform
module (TPM) technology PLC users can use
programming
• Utilize digitally signed and encrypted product firmware to guarantee software
integrity.
Some vendors already offer software suites to help users navigate and manage secu-
rity certificates, enabling simple, secure and encrypted communications right down
to the application control level.
Automation product portfolios should provide the right tools to make strong IT-type
security easy for operation technology (OT) users to apply.
45

Edge controller performance criteria 3: 7 steps to success
For industrial automation end users, the technology discussion today is less about
product acronyms like PLCs and PACs and more about delivering the right perfor- PLC
mance. Some key performance criteria are:
Micro PLCs versus
Programmable Relays
• Achieving improved design, operating and maintenance productivity
integration
• Addressing human factors associated with new workers and skill gaps
• Applying the best security in an increasingly connected world.
controller, PLC, or
Edge controllers can help end users win in each of these areas by delivering a combi-
PAC?
nation of the latest technology coupled with ease of use.
than ever
Darrell Halterman
Darrell Halterman is a senior product manager of PACSystems controllers at Emer- PLC users can use
son’s machine automation solutions business, and he is also responsible for the port- programming
folio’s control solutions modernization strategy. He enjoys working with customers to
find the right modernization strategy to enhance their existing control solutions with
the latest advancements in automation.
46
The PLC remains stronger than ever
The programmable logic controller (PLC) has been declared dead many times, 3: 7 steps to success
but it continues to thrive even in the Industry 4.0 era. CLICK PLUS PLC vs CLICK
PLC
T he programmable logic controller (PLC) has been declared dead many times. The
PLC endured in its classic form and, in reality, will never go away. Its function will
endure, but its look, shape and form factors will change to adapt to the needs of appli-
Micro PLCs versus
Programmable Relays

cations and automation architectures that today are now getting an information tech- integration
nology (IT) makeover.
The influence of initiatives like Industry 4.0 and the Industrial Internet of Things (IIoT)
is driving evolution in industrial technology at an uncommonly rapid pace. In short, the controller, PLC, or PAC?
convergence of operational technology (OT) and IT means automation architectures
The PLC remains
are looking more like IT architectures.
stronger than ever
The IT-ification of automation architectures got its first boost in 2004 when Industrial PLC users can use
Ethernet solved the connectivity dilemma of industrial devices. Where it ends is any- programming
one’s guess. Will IT giants move into the industrial space currently dominated by au-
tomation suppliers? Will automation hardware become a commodity and will future
automation solutions be purely software-based? The answers to these questions lie
somewhere between the edge and the cloud – the domains where OT technology is
quickly evolving under the influence of IT.
So what about the future of the PLC? Industrial users have clung to the hardware PLC
for decades. A PLC is reliable and repeatable – it can be picked up, dropped, swapped
out, and reprogrammed without a deep knowledge of programming languages. Over
decades, these features have saddled PLCs with ever more tasks like high-speed mo-
47


PLC
Micro PLCs versus

Programmable Relays

integration


The PLC remains

stronger than ever
PLC users can use
tion control, data handling and even process con- Courtesy: AutomationDirect, New Products cloud services without
for Engineers Database programming
trol. While the PLC excels at some of these tasks,
complex data processing is its achilles heel be-
cause PLCs lack the data structures and the programming tools necessary for complex
data operations. Fortunately, reaching this limit has helped industry users realize the
real value of the PLC and seek out other ways of handling the rest of the solution.
Arguably, recognizing the PLC’s limitations is what gave birth to the industrial edge.
The IT-ification of automation technology is taking place, but clearly the PLC is not the
right vehicle for this evolution. Instead, the PLC should be viewed simply as one of
many functions that collectively make up a complete automation solution. This function
48
is primarily logic control – monitoring inputs for change and setting outputs according Structuring with IEC 61131-
to a programmed set of rules. Like most functions, logic control can be virtualized so
that it can run on a different platform alongside other machine or process functions. As CLICK PLUS PLC vs CLICK
PLC
more tasks are off-loaded to the cloud, automation systems now have a critical need to
share data and communicate with cloud-based apps that have access to more data and Micro PLCs versus
Programmable Relays
processing power than are typically available locally on an industrial machine.
integration
What will the PLC of the future look like? Instead of a piece of ruggedized hardware,
most future PLCs will be virtualized software functions that run on a server, either PLC software benefits for
on-premise or in the cloud, as part of a complete, mostly software-based solution.
Programming tools will remain the same so that logic functions can be troubleshooted Should I use an edge
easily by plant floor staff. Private 5G networks will ensure that the PLC function can be
accessed easily from anywhere in the plant without having to open electrical cabinets. The PLC remains
In the same way, machine builders will be able to connect to a virtualized PLC during stronger than ever
all building phases, from machine construction to factory acceptance testing to on-site PLC users can use
commissioning. In fact, machine builders stand the most to benefit from PLC virtual- cloud services without
programming
ization as they learn to use this technology as the basis for lucrative aftersales revenue
streams generated from new digital services.
The PLC is not dead yet. Quite the opposite – it is aging well by adapting to the winds
of change.
This article originally appeared on Control Engineering Europe’s website.
David Humphrey
David Humphrey is research director, Europe at ARC Advisory Group.
49
PLC users can use cloud services
without programming Structuring with IEC 61131-

Original equipment manufacturers (OEMs), machine builders and others PLC
can access a no-code Industrial Internet of Things (IIoT) cloud platform,
Micro PLCs versus
providing easy-to-use data analysis tools, other functionality for bottom- Programmable Relays
line improvements PLCs power industrial data
integration
M achine builders can raise design efficiency by using cloud-based Industrial In-
ternet of Things software capabilities, building secure and scalable dashboards
for customers. By using cloud-based capabilities from a machine builder’s supplier for

programmable logic controllers (PLCs) and human-machine interface (HMI), input-out- controller, PLC, or PAC?
put (I/O) devices, variable frequency drives (VFDs) and motors, machine builders can
quickly access, in less than 30 minutes, data analysis tools to speed commissioning by than ever
using a no-coding-needed software.
PLC users can use
PLC data harvesting, easy dashboard displays programming
PLC application data can be harvested, analyzed and leveraged to increase efficien-
cy, troubleshoot problems and implement preventive maintenance. These can reduce
management overhead, leaving more time to expand business operations.
Available capabilities in such software include multi-lingual dashboards by using

drag-and-drop tools, without programming. Dashboards can be customized with
branding with logo and colors in line with the machine builder’s brands.
Users can create and assign roles and personalized dashboards as needed. Those with
appropriate security clearance can access, monitor and trouble-shoot machines. Oper-
ational machine data can be managed for performance-related analysis.
50
PLC users can use cloud services without programming

Use PLC data for machine analytics 3: 7 steps to success
By using integrate IIoT capabilities in cloud services, key machine data from the PLC
can harvested. Key performance indicators (KPIs) can be determined with central- PLC
ized and aggregated data. Such data can be used to monitor and improve process
Micro PLCs versus
reliability, reduce operational and maintenance costs, predict failures, minimize un- Programmable Relays
planned slowdowns and shutdowns and generate revenue. Machine builders can use
information to locate sales opportunities for complementary products, consumables
integration
and services. By using built-in cloud infrastructure, interfaces and functionality, it’s
easier to setup and commission a system using a simple drag and drop interface;
with a software as a service (SaaS), there’s no need to install software components,
database management services or hardware. Wizards in software can help customize
data displays, and the cloud software integrates with PLCs.
than ever
Comparative fleet analytics, KPIs, cybersecurity
When a machine builder uses data from many machines, comparative data can be PLC users can use
used to improve designs, improve maintenance and help customers more effectively.
programming
They can look at KPIs over time, at one site, many sites, regionally or globally. During
the pandemic, intelligence about machine performance can maximize remote trouble-
shooting and limit travel to the most-essential events, minimize risk.
With increased connectivity needs, machine builders seek to minimize cybersecurity

risk. Using a cloud-based architecture with multilayered security at its backbone can
use such tools as:
• Encrypted data at REST and in Transit
51
PLC users can use cloud services without programming
• Encrypted REST APIs over TLS Structuring with IEC 61131-

• MQTT X.509 certificate authentication CLICK PLUS PLC vs CLICK

PLC
• Protected with strict WAF rules against common attack patterns such as SQL injec- Micro PLCs versus
Programmable Relays
tions, cross-side scripting, and other attacks
integration
• AWS resources audited via CloudTail
• Anti-virus that runs on all machines
• Application security with role-based authentication, strict password policy
than ever
• Secure remote access machines for remote maintenance with virtual network com-
puting (VNC) to enables secure access to a PLC’s HMI via the PLC webserver with a PLC users can use
secure, private connection. cloud services without
programming
• 24/7 monitoring from a human operations center to handle any security threats
and performance issues.
Mark Hoske
Mark Hoske has been Control Engineering editor/content manager since 1994 and
in a leadership role since 1999, covering all major areas: control systems, networking
and information systems, control equipment and energy, and system integration, ev-
erything that comprises or facilitates the control loop. He has been writing about tech-
nology since 1987, writing professionally since 1982, and has a Bachelor of Science in
Journalism degree from UW-Madison. 52
PLCs
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PLCs

3 — Structuring with IEC 61131-3: 7 steps to success

12 — CLICK PLUS PLC vs CLICK PLC

13 — Micro PLCs versus Programmable Relays

25 — PLCs power industrial data integration

34 — PLC software benefits for industrial manufacturers

36 — Should I use an edge controller, PLC, or PAC?

47 — The PLC remains stronger than ever

50 — PLC users can use cloud services without programming

A s needed for a modern software development environment, the IEC 61131-3

PLC software benefits for

The PLC remains stronger

In this way, multi-disciplinary teams can cooperate in larger application programs,

as well as the user (in Structuring with IEC

• A better basis for internal communication within the multi-disciplinary develop-

• A clear separation among different responsibilities;

• A better focus on the real problem and possible solutions;

• A basis for reusable software.

Structuring is done via Structuring with IEC

3. The interfaces should be small, needing little data exchange.

4. The module interactions require explicit definition, to increase their re-usability.

PLC software benefits for

Should I use an edge

7. Configuration of the system by defining resources, linking programs with physi-

3. Definition of all operator interactions, overrides and supervisory data.

5. Definition of the required function blocks

perature control block, Structuring with IEC

This decomposition gives everybody involved a clear overview which sequences

7. Configuration of the system by defining resources, linking programs with phys-

Eelco van der Wal

Structuring with IEC 61131-

CLICK PLUS PLC vs

PLCs power industrial data

PLC software benefits for

The PLC remains stronger

PLC users can use

CLICK PLUS PLC vs CLICK PLC

Relays T he line between programmable relays and micro

Programmable relays shine in situations where the ap-

to a host of advantages as compared to a programmable relay. PLC software benefits for

What is a Micro PLC? Should I use an edge

AutomationDirect’s CLICK PLC will be used to illustrate these advantages, although

serial or Ethernet is used, Structuring with IEC 61131-

What is a Programmable Relay?

device. PLC software benefits for

either platform. PLC software benefits for

On-Board Programming The PLC remains stronger

The PLC remains stronger

2. Launch the programming software PLC software benefits for

In this CLICK example, following the instructions in about 24-pages of a welllaid-out

Don’t Forget the Documentation

software and downloaded to the device. Structuring with IEC 61131-

It is difficult to follow programming using PLC software benefits for

Should I use an edge

CLICK PLUS PLC vs CLICK

PLCs power industrial

Structuring with IEC 61131-

Structuring with IEC 61131-

CLICK PLUS PLC vs CLICK