PLCs - SUMMER EDITION..pdf for PLC education basics
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Aug 05, 2024
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About This Presentation
PLC education material
Slide Content
SUMMER EDITION
PLCs
PLCs
2Contents
3 ? PLC hardware speed, I/O, communications, redundancy,
Part 1: PLC introduction, evolution
7 ? Arduino Opta: Micro PLC with Industrial IoT Capabilities
8 ? The Micro PLC Advantage: Arduino
?
Opta
?
Redenes
Industrial Automation
21 ? How to reduce workload using reusable components
for PLCs
24 ? The Do-more BRX PLC from AutomationDirect
25 ? See the future: Four benets of software-dened
industrial controls
32 ? Nine benets of using Made in America automation
products for OEMs
40 ? Five vendors in an automation distributor: Inventory,
design assistance
46 ? Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump
Automation Controls
52 ? Back to the future of the PLC
3 ? PLC hardware speed, I/O, communications, redundancy,
Part 1: PLC introduction, evolution
7 ? Arduino Opta: Micro PLC with Industrial IoT Capabilities
8 ? The Micro PLC Advantage: Arduino
?
Opta
?
Redenes
Industrial Automation
21 ? How to reduce workload using reusable components
for PLCs
24 ? The Do-more BRX PLC from AutomationDirect
25 ? See the future: Four benets of software-dened
industrial controls
32 ? Nine benets of using Made in America automation
products for OEMs
40 ? Five vendors in an automation distributor: Inventory,
design assistance
46 ? Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump
Automation Controls
52 ? Back to the future of the PLC
fi Back to TOC 3
PLC hardware speed, I/O,
communications, redundancy, Part 1:
PLC introduction, evolution
In a November 9 webcast, “PLC series: PLC hardware speed, I/O,
communications, redundancy,” David Ubert, senior automation specialist at
Black and Veatch, and Eelco van der Wal, managing director at PLCopen,
discussed how PLC designs have changed to meet automation and control
challenges in recent years.
I
n the ever-evolving field of industrial automation, programmable logic controllers
(PLCs) have been a mainstay, adapting to the changing needs of various automation
applications. Known for their robustness and versatility, PLCs remain a preferred choice
for machine control, motion control, and even certain process control applications.
However, as the demands of modern automation grow increasingly complex, it’s essen-
tial to understand where PLCs fit best in today’s industrial landscape.
In a November 9 webcast, “PLC series: PLC hardware speed, I/O, communications,
redundancy,” David Ubert, senior automation specialist at Black and Veatch, and Eelco
van der Wal, managing director at PLCopen, discussed scenarios where PLCs are most
effective, how their designs have changed to meet contemporary automation challeng-
es, and what key criteria end-users should pay attention to when selecting PLCs for
specific applications.
The transcript of their presentation has been provided with minor edits and adaptations.
PLC hardware speed, I/O,
communications, redundancy, Part 1:
PLC introduction, evolution
In a November 9 webcast, “PLC series: PLC hardware speed, I/O,
communications, redundancy,” David Ubert, senior automation specialist at
Black and Veatch, and Eelco van der Wal, managing director at PLCopen,
discussed how PLC designs have changed to meet automation and control
challenges in recent years.
I
n the ever-evolving field of industrial automation, programmable logic controllers
(PLCs) have been a mainstay, adapting to the changing needs of various automation
applications. Known for their robustness and versatility, PLCs remain a preferred choice
for machine control, motion control, and even certain process control applications.
However, as the demands of modern automation grow increasingly complex, it’s essen-
tial to understand where PLCs fit best in today’s industrial landscape.
In a November 9 webcast, “PLC series: PLC hardware speed, I/O, communications,
redundancy,” David Ubert, senior automation specialist at Black and Veatch, and Eelco
van der Wal, managing director at PLCopen, discussed scenarios where PLCs are most
effective, how their designs have changed to meet contemporary automation challeng-
es, and what key criteria end-users should pay attention to when selecting PLCs for
specific applications.
The transcript of their presentation has been provided with minor edits and adaptations.
fl Back to TOC
PLC hardware speed, I/O, communications, redundancy, Part 1 4
Introduction to pro-
grammable logic con-
trollers (PLCs)
David Ubert: Today, I am ex-
cited to discuss programmable
logic controllers (PLCs), focus-
ing on their hardware speed
and communication systems.
Throughout my career, I have
extensively worked with PLCs.
To begin, I’ll cover some basic
concepts. Recognizing the diverse audience, it’s important to start with a brief over-
view of PLCs’ origin. PLCs emerged in the late 1960s and early 1970s, predominantly
in the automotive industry, which significantly drove their development. The industry
aimed to replace traditional relays with more advanced and efficient technology, en-
hancing their competitive edge.
Evolution and applications of PLCs
An interesting aspect of this evolution is the initial goal to replace relays with PLCs.
Despite this, even today, relays maintain a high current rating on contacts, a feature less
common in PLCs. However, PLCs have been improving substantially in this regard. It’s
common to see PLC panels incorporating isolation relays, serving specific purposes.
Technology, inherently, is fascinating, especially considering its non-linear progression.
Technological advancement is indeed exponential. Reflecting on history, for thousands
of years, transportation relied on camels, horses, and buggies. However, within a rela-
PLC hardware speed, I/O, communications, redundancy, Part 1 4
Introduction to pro-
grammable logic con-
trollers (PLCs)
David Ubert: Today, I am ex-
cited to discuss programmable
logic controllers (PLCs), focus-
ing on their hardware speed
and communication systems.
Throughout my career, I have
extensively worked with PLCs.
To begin, I’ll cover some basic
concepts. Recognizing the diverse audience, it’s important to start with a brief over-
view of PLCs’ origin. PLCs emerged in the late 1960s and early 1970s, predominantly
in the automotive industry, which significantly drove their development. The industry
aimed to replace traditional relays with more advanced and efficient technology, en-
hancing their competitive edge.
Evolution and applications of PLCs
An interesting aspect of this evolution is the initial goal to replace relays with PLCs.
Despite this, even today, relays maintain a high current rating on contacts, a feature less
common in PLCs. However, PLCs have been improving substantially in this regard. It’s
common to see PLC panels incorporating isolation relays, serving specific purposes.
Technology, inherently, is fascinating, especially considering its non-linear progression.
Technological advancement is indeed exponential. Reflecting on history, for thousands
of years, transportation relied on camels, horses, and buggies. However, within a rela-
fi Back to TOC
PLC hardware speed, I/O, communications, redundancy, Part 1 5
tively short span – from the inven-
tion of the automobile in 1885 to
landing a man on the moon less
than 90 years later – technology
has rapidly advanced. This expo-
nential growth makes the field
exhilarating for professionals like
myself. Embracing new technolo-
gy leads to innovative ideas and
even more advanced technolo-
gies, as evidenced in the ongoing
development of PLCs.
The importance of
keeping up with tech-
nological advancements
It’s crucial to stay abreast of tech-
nological advancements. I’ve
encountered clients hesitant to
adopt new technologies due to
fear of unfamiliarity, potential
malfunctions, or lack of under-
standing. However, it’s imperative
to grow with technology and be
a part of its evolution. PLCs are
utilized across various industries.
Scan to access our
digital catalog
The industrial
tools for your
IoT revolution
Hardware products, development
environments, and cloud services to
create your own application with ease.
arduino.cc/pro
PLC hardware speed, I/O, communications, redundancy, Part 1 5
tively short span – from the inven-
tion of the automobile in 1885 to
landing a man on the moon less
than 90 years later – technology
has rapidly advanced. This expo-
nential growth makes the field
exhilarating for professionals like
myself. Embracing new technolo-
gy leads to innovative ideas and
even more advanced technolo-
gies, as evidenced in the ongoing
development of PLCs.
The importance of
keeping up with tech-
nological advancements
It’s crucial to stay abreast of tech-
nological advancements. I’ve
encountered clients hesitant to
adopt new technologies due to
fear of unfamiliarity, potential
malfunctions, or lack of under-
standing. However, it’s imperative
to grow with technology and be
a part of its evolution. PLCs are
utilized across various industries.
Scan to access our
digital catalog
The industrial
tools for your
IoT revolution
Hardware products, development
environments, and cloud services to
create your own application with ease.
arduino.cc/pro
fi Back to TOC
PLC hardware speed, I/O, communications, redundancy, Part 1 6
For example, the power sector heavily relies on PLC and networking equipment, given
its critical nature. Water and wastewater management is another significant area where I
have considerable experience. These facilities extensively use control and PLC systems.
Diverse applications of PLCs in industry
Industries like Frito-Lay, Coca-Cola, Pepsi, and even the space program regularly em-
ploy PLCs. My experience includes programming and designing numerous PLC sys-
tems. While jokingly saying, “We’re not launching the Space Shuttle here with this
PLC,” the reality is that it’s possible due to their versatility. PLCs have a wide range of
applications, from communication systems to batching systems. For instance, on the
screen’s left side, a palletizer, typically featuring a robotic arm, moves materials be-
tween conveyors and locations, exemplifying a perfect PLC application. At the screen’s
center top, you see a typical batching system, involving transferring and mixing sub-
stances in tanks to produce a final product – another excellent application for PLCs.
Lastly, humorously, while a PLC might be overkill for a home sump pump, as shown on
the right side, it illustrates the potential for PLCs in various applications.
Different manufacturers offer a variety of PLCs, each with unique platforms. These plat-
forms vary in size, with some designed for extensive input/output (IO) handling, while
others manage minimal IO. This diversity caters to a wide range of applications. Addi-
tionally, certain industries, like pulp and paper or the steel industry, require high-speed
applications. Historically, these needs were addressed by Distributed Control Systems
(DCS), leading to a debate over the superiority of DCS systems compared to PLCs. A
DCS system, placing control at required locations, has historically been equipped with
high-speed networks, making it ideal for such applications.
Control Engineering
PLC hardware speed, I/O, communications, redundancy, Part 1 6
For example, the power sector heavily relies on PLC and networking equipment, given
its critical nature. Water and wastewater management is another significant area where I
have considerable experience. These facilities extensively use control and PLC systems.
Diverse applications of PLCs in industry
Industries like Frito-Lay, Coca-Cola, Pepsi, and even the space program regularly em-
ploy PLCs. My experience includes programming and designing numerous PLC sys-
tems. While jokingly saying, “We’re not launching the Space Shuttle here with this
PLC,” the reality is that it’s possible due to their versatility. PLCs have a wide range of
applications, from communication systems to batching systems. For instance, on the
screen’s left side, a palletizer, typically featuring a robotic arm, moves materials be-
tween conveyors and locations, exemplifying a perfect PLC application. At the screen’s
center top, you see a typical batching system, involving transferring and mixing sub-
stances in tanks to produce a final product – another excellent application for PLCs.
Lastly, humorously, while a PLC might be overkill for a home sump pump, as shown on
the right side, it illustrates the potential for PLCs in various applications.
Different manufacturers offer a variety of PLCs, each with unique platforms. These plat-
forms vary in size, with some designed for extensive input/output (IO) handling, while
others manage minimal IO. This diversity caters to a wide range of applications. Addi-
tionally, certain industries, like pulp and paper or the steel industry, require high-speed
applications. Historically, these needs were addressed by Distributed Control Systems
(DCS), leading to a debate over the superiority of DCS systems compared to PLCs. A
DCS system, placing control at required locations, has historically been equipped with
high-speed networks, making it ideal for such applications.
Control Engineering
Arduino Opta: Micro PLC with Industrial
IoT Capabilities
Arduino Opta is a secure, easy-to-use micro PLC with Industrial IoT
capabilities. Designed in partnership with Finder, leading industrial
and building automation device manufacturer, it allows professionals
to scale up automation projects while taking advantage of the open
and widely known Arduino ecosystem. Thanks to its computing
power, Arduino Opta enables a wide range of real-time control,
monitoring and predictive maintenance applications.
Arduino Opta: Micro PLC with Industrial IoT Capabilities 7 Back to TOC
T
raditional Programmable Logic Controllers (PLCs)
have been the cornerstone of automation and con-
trol systems since the 1970s, offering robust management
of manufacturing processes and machinery. However, as
technology evolves, so does the need for more versatile
and cost-effective solutions. Enter micro PLCs, compact
yet powerful devices that are reshaping the landscape of
industrial automation. Their aim is not to change core au-
tomation and control, but rather to simplify any behavioral
and diagnostic elements and to offer an effective alterna-
tive to simple automation needs.
Strengths and Weaknesses of Micro PLCs
Micro PLCs represent a paradigm shift in automation tech-
nology, offering an add-on approach with interoperability
to their existing full-size counterparts, as well as a com-
pelling alternative for certain use-cases. These pint-sized
powerhouses may come with certain limitations, yet offer
significant advantages that outweigh these constraints and
make them ideal for a wide range of applications across
industries.
Memory size constraints, restricted embedded I/O counts,
and sub-millisecond scan time limitations with certain
devices are often listed as common pitfalls. It’s worth not-
ing that careful selection and planning allow engineers to
The Micro PLC
Advantage:
Arduino
®
Opta
®
Redefines
Industrial
Automation
raditional Programmable Logic Controllers (PLCs)
have been the cornerstone of automation and con-
trol systems since the 1970s, offering robust management
of manufacturing processes and machinery. However, as
technology evolves, so does the need for more versatile
and cost-effective solutions. Enter micro PLCs, compact
yet powerful devices that are reshaping the landscape of
industrial automation. Their aim is not to change core au-
tomation and control, but rather to simplify any behavioral
and diagnostic elements and to offer an effective alterna-
tive to simple automation needs.
Strengths and Weaknesses of Micro PLCs
Micro PLCs represent a paradigm shift in automation tech-
nology, offering an add-on approach with interoperability
to their existing full-size counterparts, as well as a com-
pelling alternative for certain use-cases. These pint-sized
powerhouses may come with certain limitations, yet offer
significant advantages that outweigh these constraints and
make them ideal for a wide range of applications across
industries.
Memory size constraints, restricted embedded I/O counts,
and sub-millisecond scan time limitations with certain
devices are often listed as common pitfalls. It’s worth not-
ing that careful selection and planning allow engineers to
The Micro PLC
Advantage:
Arduino
®
Opta
®
Redefines
Industrial
Automation
fi Back to TOC
The Micro PLC Advantage: Arduino
?
Opta
?
Redefines Industrial Automation 9
mitigate these limitations, to ensure optimal performance in a variety of projects they
may need to tackle. For example, memory limitations can be bypassed with micro PLCs
that leverage USB ports or micro SD ports to store recipe data. In any case, the crucial
step is to closely evaluate the fine print in products’ manuals, as each manufacturer has
its own specifications.
On the other hand, micro PLCs almost universally stand out for their versatility
and cost-effectiveness. Unlike traditional PLCs, which often rely on a single massive
processor to control entire production lines, micro PLCs allow for distributed control
systems with multiple devices communicating seamlessly to orchestrate complex tasks
across the factory floor. This approach not only improves efficiency but also reduces
costs, making micro PLCs an increasingly popular choice in industrial settings.
IN A NUTSHELL
Micro PLCs are not merely scaled-down versions of traditional PLCs.
Rather, they are optimized for activities that don’t require core automation
tasks with extensive I/O or processing power. With their compact
form factor and robust performance, micro PLCs offer a tailored solution
for a wide range of automation projects.
Choosing the right micro PLC for a project requires careful consideration of factors
such as I/O counts, motion control capabilities, and operator interfaces. While micro
PLCs may not offer the same level of connectivity as their larger counterparts, they ex-
cel in smaller or distributed systems where affordability and efficiency are paramount.
The Micro PLC Advantage: Arduino
?
Opta
?
Redefines Industrial Automation 9
mitigate these limitations, to ensure optimal performance in a variety of projects they
may need to tackle. For example, memory limitations can be bypassed with micro PLCs
that leverage USB ports or micro SD ports to store recipe data. In any case, the crucial
step is to closely evaluate the fine print in products’ manuals, as each manufacturer has
its own specifications.
On the other hand, micro PLCs almost universally stand out for their versatility
and cost-effectiveness. Unlike traditional PLCs, which often rely on a single massive
processor to control entire production lines, micro PLCs allow for distributed control
systems with multiple devices communicating seamlessly to orchestrate complex tasks
across the factory floor. This approach not only improves efficiency but also reduces
costs, making micro PLCs an increasingly popular choice in industrial settings.
IN A NUTSHELL
Micro PLCs are not merely scaled-down versions of traditional PLCs.
Rather, they are optimized for activities that don’t require core automation
tasks with extensive I/O or processing power. With their compact
form factor and robust performance, micro PLCs offer a tailored solution
for a wide range of automation projects.
Choosing the right micro PLC for a project requires careful consideration of factors
such as I/O counts, motion control capabilities, and operator interfaces. While micro
PLCs may not offer the same level of connectivity as their larger counterparts, they ex-
cel in smaller or distributed systems where affordability and efficiency are paramount.
fl Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 10
Arduino Opta: the “Swiss Army Knife” of Industrial Automation
The Arduino Opta is a groundbreaking micro PLC, successfully adopted to integrate
into local automation solutions as
well as IoT applications due to its
security features, versatile edge AI
capability, and built-in connectivity
options. It allows users to avoid
vendor lock-in and is suitable even
for beginners in industrial and
building automation, remote moni-
toring and control, and IoT.
Discover Opta’s outstanding fea-
tures:
• Programming flexibility: Opta gives users plenty of choices because it can be
programmed with the key IEC 61131-3 languages (including Ladder Logic Diagram
and Function Block Diagram) as well as within the Arduino environment, also re-
lying on many ready-to-use software libraries and sketches. In addition, the two
approaches can be combined to further expand capabilities.
• Strong computing power: At the heart of the Arduino Opta lies the powerful
STM32H747XI dual-core Arm
®
Cortex
®
-M7 +M4 MCU, delivering unrivaled perfor-
mance for real-time control, monitoring, and predictive maintenance applications.
With this advanced technology, users can harness the full potential of their auto-
mation systems, ensuring optimal efficiency and productivity.
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 10
Arduino Opta: the “Swiss Army Knife” of Industrial Automation
The Arduino Opta is a groundbreaking micro PLC, successfully adopted to integrate
into local automation solutions as
well as IoT applications due to its
security features, versatile edge AI
capability, and built-in connectivity
options. It allows users to avoid
vendor lock-in and is suitable even
for beginners in industrial and
building automation, remote moni-
toring and control, and IoT.
Discover Opta’s outstanding fea-
tures:
• Programming flexibility: Opta gives users plenty of choices because it can be
programmed with the key IEC 61131-3 languages (including Ladder Logic Diagram
and Function Block Diagram) as well as within the Arduino environment, also re-
lying on many ready-to-use software libraries and sketches. In addition, the two
approaches can be combined to further expand capabilities.
• Strong computing power: At the heart of the Arduino Opta lies the powerful
STM32H747XI dual-core Arm
®
Cortex
®
-M7 +M4 MCU, delivering unrivaled perfor-
mance for real-time control, monitoring, and predictive maintenance applications.
With this advanced technology, users can harness the full potential of their auto-
mation systems, ensuring optimal efficiency and productivity.
fl Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 11
• A wealth of connectivity options: With different variants offering Ethernet,
RS485, or Wi-Fi
®
/Bluetooth
®
capabilities, this micro PLC seamlessly integrates
with your preferred platform – whether that’s the Arduino
®
Cloud or a third-party
service such as AWS and Azure – providing unparalleled visibility and control over
your automation systems through real-time dashboards. Fieldbus communication is
guaranteed using standard protocols like Modbus RTU and TCP, allowing Opta to
connect to a wide range of sensors, actuators and existing subsystems.
• Industrial-strength security: Security is paramount in today’s interconnected world,
and the Arduino Opta is designed with this in mind. It supports Over-The-Air (OTA)
firmware updates and ensures data security from the hardware to the Cloud thanks
to the onboard secure element and X.509 Standard compliance. In addition, it also
undergoes regular cybersecurity assessments carried out with leading providers.
• Ideal for Edge AI: Opta can be used for additional intelligence in any industrial
environment, with applications including behavioral and diagnostic tasks such as
anomaly detection, predictive maintenance and energy efficiency within control
and automation solutions.
“ With Opta, we lower barriers to industrial automation en-
abling a broad range of projects that were ‘unthinkable’ or
‘unapproachable’ not long ago. We’ve worked hard to provide
high-performance hardware and super-secure connectivity at a
compelling price point, combined with flexibility in the choice
of the preferred programming paradigm between Arduino lan-
guage and all IEC 61131-3 languages.”
– Fabio Violante, CEO of Arduino
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 11
• A wealth of connectivity options: With different variants offering Ethernet,
RS485, or Wi-Fi
®
/Bluetooth
®
capabilities, this micro PLC seamlessly integrates
with your preferred platform – whether that’s the Arduino
®
Cloud or a third-party
service such as AWS and Azure – providing unparalleled visibility and control over
your automation systems through real-time dashboards. Fieldbus communication is
guaranteed using standard protocols like Modbus RTU and TCP, allowing Opta to
connect to a wide range of sensors, actuators and existing subsystems.
• Industrial-strength security: Security is paramount in today’s interconnected world,
and the Arduino Opta is designed with this in mind. It supports Over-The-Air (OTA)
firmware updates and ensures data security from the hardware to the Cloud thanks
to the onboard secure element and X.509 Standard compliance. In addition, it also
undergoes regular cybersecurity assessments carried out with leading providers.
• Ideal for Edge AI: Opta can be used for additional intelligence in any industrial
environment, with applications including behavioral and diagnostic tasks such as
anomaly detection, predictive maintenance and energy efficiency within control
and automation solutions.
“ With Opta, we lower barriers to industrial automation en-
abling a broad range of projects that were ‘unthinkable’ or
‘unapproachable’ not long ago. We’ve worked hard to provide
high-performance hardware and super-secure connectivity at a
compelling price point, combined with flexibility in the choice
of the preferred programming paradigm between Arduino lan-
guage and all IEC 61131-3 languages.”
– Fabio Violante, CEO of Arduino
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 12
Engineered with precision and expertise, this secure and user-friendly device boasts
Industrial IoT capabilities, empowering professionals to scale up automation projects
with ease. Its seamless integration with the Arduino ecosystem further facilitates
deployment.
Arduino Opta’s mon-
itoring and control
capabilities can be
augmented with I/O
expansion modules:
Arduino
®
Pro Opta
®
Ext D1608E and
Arduino
®
Pro Opta
®
Ext D1608S multi-
ply real-time control
points with 16 pro-
grammable inputs and 8 digital (electromechanical or solid-state) relay outputs;
Arduino
®
Pro Opta
®
Ext A0602 instead allows users to configure new analog I/O
to interact with 0-10 V and 0/4-20 mA signals, and get temperature values through
PT100, diversifying data acquisition capabilities and expanding actuation possibili-
ties. Arduino ecosystem partners are also creating additional modules, such as the
Wireless for Arduino Opta expansion by Blues Wireless, adding cellular+Wi-Fi
®
and LoRaWAN
®
connectivity.
Its ease of use has made Opta a favorite tool also in rapid prototyping, education and
training. Arduino itself has recently launched the Arduino
®
PLC Starter Kit, based
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 12
Engineered with precision and expertise, this secure and user-friendly device boasts
Industrial IoT capabilities, empowering professionals to scale up automation projects
with ease. Its seamless integration with the Arduino ecosystem further facilitates
deployment.
Arduino Opta’s mon-
itoring and control
capabilities can be
augmented with I/O
expansion modules:
Arduino
®
Pro Opta
®
Ext D1608E and
Arduino
®
Pro Opta
®
Ext D1608S multi-
ply real-time control
points with 16 pro-
grammable inputs and 8 digital (electromechanical or solid-state) relay outputs;
Arduino
®
Pro Opta
®
Ext A0602 instead allows users to configure new analog I/O
to interact with 0-10 V and 0/4-20 mA signals, and get temperature values through
PT100, diversifying data acquisition capabilities and expanding actuation possibili-
ties. Arduino ecosystem partners are also creating additional modules, such as the
Wireless for Arduino Opta expansion by Blues Wireless, adding cellular+Wi-Fi
®
and LoRaWAN
®
connectivity.
Its ease of use has made Opta a favorite tool also in rapid prototyping, education and
training. Arduino itself has recently launched the Arduino
®
PLC Starter Kit, based
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 13
on the Opta WiFi and Arduino PLC IDE, offering a training solution that plugs right
into the future of industrial automation. The kit, integration-ready with industri-
al simulated systems, is designed to introduce students in vocational institutes and
tech-oriented academies to IEC 61131-3 standard programming languages and Mod-
bus communications.
In conclusion, the Opta represents a paradigm shift in industrial automation, offering
a comprehensive solution for professionals seeking to elevate their projects to new
heights. With its cutting-edge technology, robust security features, and seamless in-
tegration with the Arduino ecosystem, the Opta is poised to revolutionize the way we
approach automation.
Harnessing the Power of Micro PLCs:
Use Cases and Applications
The versatility of micro PLCs extends far beyond traditional industrial settings, with
applications ranging from adding IoT, diagnostics, and behavioral context to existing
automation systems all the way to building simple automation use cases.
1. Industrial Automation
In manufacturing plants and assembly lines, micro PLCs can play a crucial role in con-
necting legacy machinery, monitoring processes, collecting data, and sometimes also
implementing control. Their compact size and robust performance make them ideal for
optimizing efficiency and productivity in a variety of environments. They also allow in-
teroperability with existing automation systems (e.g. PLCs, DCS, SCADA) and therefore
are purely complementary.
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 13
on the Opta WiFi and Arduino PLC IDE, offering a training solution that plugs right
into the future of industrial automation. The kit, integration-ready with industri-
al simulated systems, is designed to introduce students in vocational institutes and
tech-oriented academies to IEC 61131-3 standard programming languages and Mod-
bus communications.
In conclusion, the Opta represents a paradigm shift in industrial automation, offering
a comprehensive solution for professionals seeking to elevate their projects to new
heights. With its cutting-edge technology, robust security features, and seamless in-
tegration with the Arduino ecosystem, the Opta is poised to revolutionize the way we
approach automation.
Harnessing the Power of Micro PLCs:
Use Cases and Applications
The versatility of micro PLCs extends far beyond traditional industrial settings, with
applications ranging from adding IoT, diagnostics, and behavioral context to existing
automation systems all the way to building simple automation use cases.
1. Industrial Automation
In manufacturing plants and assembly lines, micro PLCs can play a crucial role in con-
necting legacy machinery, monitoring processes, collecting data, and sometimes also
implementing control. Their compact size and robust performance make them ideal for
optimizing efficiency and productivity in a variety of environments. They also allow in-
teroperability with existing automation systems (e.g. PLCs, DCS, SCADA) and therefore
are purely complementary.
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 14
Global design company Steelcase, for example, improved their workflow by building a
simple and cost-effective application around the Arduino Opta.
When a machine seems to not work properly at random, “Traditionally, you’d get a
person out there with a stopwatch and a clipboard, but it could be days or weeks be-
fore they might see this issue arise,” says Steven Jones, a technical process consultant
at the company.
Wiring Arduino’s secure and easy-to-use micro PLC into existing equipment allowed
Steelcase to monitor signals that indicate when a specific problem was occurring. With
this information, control engineers, electricians and developers within the company
were able to quickly create a solution to provide visibility over any critical IoT events on
the machine, via custom dashboards.
“That wasn’t so easy to do a decade or so ago, but the IoT tools becoming available
are much more cost-effective than they have been in the past. I started working in
factories in pre-internet times: the technology now is available to do things that were
never imaginable before,” says Jones. “Opta has digital inputs and digital outputs,
analog inputs, outputs, everything that a regular PLC would have.”
2. Remote Monitoring and Control
Micro PLCs with wireless connectivity capabilities are invaluable for remote monitoring
and control of equipment and systems in remote or inaccessible locations. From oil
and gas facilities to utility networks, micro PLCs offer a cost-effective solution for main-
taining operational visibility and ensuring uptime.
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 14
Global design company Steelcase, for example, improved their workflow by building a
simple and cost-effective application around the Arduino Opta.
When a machine seems to not work properly at random, “Traditionally, you’d get a
person out there with a stopwatch and a clipboard, but it could be days or weeks be-
fore they might see this issue arise,” says Steven Jones, a technical process consultant
at the company.
Wiring Arduino’s secure and easy-to-use micro PLC into existing equipment allowed
Steelcase to monitor signals that indicate when a specific problem was occurring. With
this information, control engineers, electricians and developers within the company
were able to quickly create a solution to provide visibility over any critical IoT events on
the machine, via custom dashboards.
“That wasn’t so easy to do a decade or so ago, but the IoT tools becoming available
are much more cost-effective than they have been in the past. I started working in
factories in pre-internet times: the technology now is available to do things that were
never imaginable before,” says Jones. “Opta has digital inputs and digital outputs,
analog inputs, outputs, everything that a regular PLC would have.”
2. Remote Monitoring and Control
Micro PLCs with wireless connectivity capabilities are invaluable for remote monitoring
and control of equipment and systems in remote or inaccessible locations. From oil
and gas facilities to utility networks, micro PLCs offer a cost-effective solution for main-
taining operational visibility and ensuring uptime.
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 15
Among the huge range of applications, Arduino Opta has been deployed to monitor
and adjust tank levels, in-situ and remotely, making everyday tasks more efficient in
any enterprise that uses transport and storage tanks, such as water treatment plants.
Level monitoring is essential in many commercial and residential applications – such
as water dispensers, water evaporators, streamers, boiler monitoring systems, heating
systems, washing machines, steam irons, automated coffee machines, and so on. With
its industrial IoT capabilities and ease of development, the Opta micro PLC can be the
perfect solution in all of these cases.
On the factory floor, Opta can also be at the heart of smart conveyor systems, able
to sort packages based on size – for a bill of materials that totaled approximately
300 US dollars, proving how convenient it can be to swap traditional PLCs with Opta to
expand an IIoT system.
An industrial air compressor company can leverage Opta to seamlessly receive re-
al-time machine information and sensor data, such as temperature readings, from its
equipment deployed in the field. Opta securely transmits this data to complex cloud
architectures, enabling simultaneous internal data collection and customer-facing
dashboards. By providing customers with transparent access to equipment perfor-
mance metrics, the company fosters trust and strengthens relationships. Opta’s cost-ef-
fectiveness and ease of development make it a compelling choice for industrial IoT
applications.
Beyond that, Opta has proven to be the perfect solution in a variety of different con-
texts.
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 15
Among the huge range of applications, Arduino Opta has been deployed to monitor
and adjust tank levels, in-situ and remotely, making everyday tasks more efficient in
any enterprise that uses transport and storage tanks, such as water treatment plants.
Level monitoring is essential in many commercial and residential applications – such
as water dispensers, water evaporators, streamers, boiler monitoring systems, heating
systems, washing machines, steam irons, automated coffee machines, and so on. With
its industrial IoT capabilities and ease of development, the Opta micro PLC can be the
perfect solution in all of these cases.
On the factory floor, Opta can also be at the heart of smart conveyor systems, able
to sort packages based on size – for a bill of materials that totaled approximately
300 US dollars, proving how convenient it can be to swap traditional PLCs with Opta to
expand an IIoT system.
An industrial air compressor company can leverage Opta to seamlessly receive re-
al-time machine information and sensor data, such as temperature readings, from its
equipment deployed in the field. Opta securely transmits this data to complex cloud
architectures, enabling simultaneous internal data collection and customer-facing
dashboards. By providing customers with transparent access to equipment perfor-
mance metrics, the company fosters trust and strengthens relationships. Opta’s cost-ef-
fectiveness and ease of development make it a compelling choice for industrial IoT
applications.
Beyond that, Opta has proven to be the perfect solution in a variety of different con-
texts.
fl Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 16
Stratford Festival, North America’s largest classical repertory theater company, has
successfully employed Opta in building a large, custom elevating platform that sits
flush with the stage floor and silently locks for safety without disrupting performances.
The theater’s Head of Automation, Ian Phillips, was pleasantly surprised to discover
that Opta was not only powerful and secure but also UL-certified, meaning it has met
the standards required for safety testing in the United States. Even while costing a
fraction of similar products on the market, Opta provided the ideal number of I/O and
built-in Wi-Fi/Bluetooth
®
Low Energy connectivity, allowing for effortless integration
into the existing control system platform – identified as a regular I/O device. The af-
fordable price tag meant Phillips could purchase multiple units while staying under
budget and avoiding a cumbersome budget approval process.
3. Building Automation
Commercial and residential buildings benefit from the use of micro PLCs for tasks such
as energy monitoring, HVAC monitoring and control, lighting management, and en-
abling security systems with additional data. These devices enable building owners to
enhance comfort and safety, optimize energy usage, and improve overall operational
efficiency.
For example, Arduino Opta can easily be programmed to open and close roller win-
dow shades using a DC motor at specific hours every day. It could also adjust the
shades responding automatically to sunlight conditions, or people’s presence, thanks
to appropriate sensors. Extending the same concept, home automation systems can
be extended to suit entire hotels and rental properties, creating smart accommoda-
tion solutions that offer guests an enhanced experience. Arduino Opta can connect to
and monitor various devices and subsystems such as heating, ventilation, air condition-
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 16
Stratford Festival, North America’s largest classical repertory theater company, has
successfully employed Opta in building a large, custom elevating platform that sits
flush with the stage floor and silently locks for safety without disrupting performances.
The theater’s Head of Automation, Ian Phillips, was pleasantly surprised to discover
that Opta was not only powerful and secure but also UL-certified, meaning it has met
the standards required for safety testing in the United States. Even while costing a
fraction of similar products on the market, Opta provided the ideal number of I/O and
built-in Wi-Fi/Bluetooth
®
Low Energy connectivity, allowing for effortless integration
into the existing control system platform – identified as a regular I/O device. The af-
fordable price tag meant Phillips could purchase multiple units while staying under
budget and avoiding a cumbersome budget approval process.
3. Building Automation
Commercial and residential buildings benefit from the use of micro PLCs for tasks such
as energy monitoring, HVAC monitoring and control, lighting management, and en-
abling security systems with additional data. These devices enable building owners to
enhance comfort and safety, optimize energy usage, and improve overall operational
efficiency.
For example, Arduino Opta can easily be programmed to open and close roller win-
dow shades using a DC motor at specific hours every day. It could also adjust the
shades responding automatically to sunlight conditions, or people’s presence, thanks
to appropriate sensors. Extending the same concept, home automation systems can
be extended to suit entire hotels and rental properties, creating smart accommoda-
tion solutions that offer guests an enhanced experience. Arduino Opta can connect to
and monitor various devices and subsystems such as heating, ventilation, air condition-
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 17
ing, lights, and door locks, receiving data from sensors and users and processing them
to trigger appropriate actions in the room.
Improved energy management and the ability to operate devices on-demand within
power grids is becoming increasingly interesting – as it promises significant cost sav-
ings, reduced environmental impact, and enhanced performance. In this context, Opta
prioritizes security with elements that ensure data integrity, encryption, and secure
certificate storage. This makes it a suitable IoT node for creating a private and secure
IIoT network, for example to support energy management at home, in the office or
even in a factory. Taking one step further, users can also integrate the Arduino Cloud
into their smart solution to be connected and updated 24/7, and even add self-adjust-
ment capabilities along with the option to operate the connected devices on-demand
or based on pre-set triggers.
For AMB Vapor Monitoring, which offers cloud-based control and reporting for their
sub-slab depressurization systems, a combination of Arduino Opta and Arduino Cloud
was the key to a revolutionary solution that can efficiently collect data from a central-
ized network of up to 200+ subsurface gas sensors and provide real-time, reliable data
24/7. An automation technician within the company leveraged community resources
to learn C/C++ and develop a custom application, highlighting the accessibility and
support provided by Arduino. All in all, AMB went from idea to installation in a matter
of months, building professional, functional dashboards in mere hours: “And it works.
It just literally works,” says co-founder Mark Bishop.
4. IoT Applications
The Internet of Things (IoT) is revolutionizing industries worldwide, and micro PLCs
are at the forefront of this transformation. With their small form factor and connectivity
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 17
ing, lights, and door locks, receiving data from sensors and users and processing them
to trigger appropriate actions in the room.
Improved energy management and the ability to operate devices on-demand within
power grids is becoming increasingly interesting – as it promises significant cost sav-
ings, reduced environmental impact, and enhanced performance. In this context, Opta
prioritizes security with elements that ensure data integrity, encryption, and secure
certificate storage. This makes it a suitable IoT node for creating a private and secure
IIoT network, for example to support energy management at home, in the office or
even in a factory. Taking one step further, users can also integrate the Arduino Cloud
into their smart solution to be connected and updated 24/7, and even add self-adjust-
ment capabilities along with the option to operate the connected devices on-demand
or based on pre-set triggers.
For AMB Vapor Monitoring, which offers cloud-based control and reporting for their
sub-slab depressurization systems, a combination of Arduino Opta and Arduino Cloud
was the key to a revolutionary solution that can efficiently collect data from a central-
ized network of up to 200+ subsurface gas sensors and provide real-time, reliable data
24/7. An automation technician within the company leveraged community resources
to learn C/C++ and develop a custom application, highlighting the accessibility and
support provided by Arduino. All in all, AMB went from idea to installation in a matter
of months, building professional, functional dashboards in mere hours: “And it works.
It just literally works,” says co-founder Mark Bishop.
4. IoT Applications
The Internet of Things (IoT) is revolutionizing industries worldwide, and micro PLCs
are at the forefront of this transformation. With their small form factor and connectivity
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 18
options, these devices are ideal for building sensor nodes, data loggers, and remote
monitoring systems for a variety of IoT applications.
Arduino Opta WiFi can also be effectively employed to retrofit common pieces of
equipment to transform them into connected devices. By replacing the original
controller in an injection molding machine, for example, Arduino’s micro PLC allows
users to reap all the benefits of connected things and data analysis without huge in-
vestments: upgrading to advanced automation capabilities means they can monitor
and control the machine remotely via intuitive dashboards, for real-time oversight of
production cycles, performance metrics, and equipment status from anywhere with an
Internet connection. Additionally, Opta WiFi is equipped with RS485 communication
capabilities, enabling seamless integration with an external power meter. This provides
valuable insights into energy consumption, production output, material usage, and
equipment health. The collected data is then analyzed through dedicated dashboards,
offering information about operational efficiency and potential issues. By leveraging
this data, businesses can proactively schedule maintenance and repairs, minimizing
downtime and optimizing production processes.
5. Education, Training, and Rapid Prototyping
Cost-effective and functional, micro PLCs like Arduino Opta are invaluable tools for
education, training, and rapid prototyping projects. Whether teaching electronics con-
cepts in the classroom or experimenting with automation ideas in an R&D department,
micro PLCs offer a hands-on learning experience that inspires innovation and out-of-
the-box thinking for engineers, technicians, and anyone interested in technology.
In addition to the PLC Starter Kit, Arduino has invested huge resources on developing
a comprehensive training program for professionals seeking the highly recognized
The Micro PLC Advantage: Arduino
®
Opta
®
Redeflnes Industrial Automation 18
options, these devices are ideal for building sensor nodes, data loggers, and remote
monitoring systems for a variety of IoT applications.
Arduino Opta WiFi can also be effectively employed to retrofit common pieces of
equipment to transform them into connected devices. By replacing the original
controller in an injection molding machine, for example, Arduino’s micro PLC allows
users to reap all the benefits of connected things and data analysis without huge in-
vestments: upgrading to advanced automation capabilities means they can monitor
and control the machine remotely via intuitive dashboards, for real-time oversight of
production cycles, performance metrics, and equipment status from anywhere with an
Internet connection. Additionally, Opta WiFi is equipped with RS485 communication
capabilities, enabling seamless integration with an external power meter. This provides
valuable insights into energy consumption, production output, material usage, and
equipment health. The collected data is then analyzed through dedicated dashboards,
offering information about operational efficiency and potential issues. By leveraging
this data, businesses can proactively schedule maintenance and repairs, minimizing
downtime and optimizing production processes.
5. Education, Training, and Rapid Prototyping
Cost-effective and functional, micro PLCs like Arduino Opta are invaluable tools for
education, training, and rapid prototyping projects. Whether teaching electronics con-
cepts in the classroom or experimenting with automation ideas in an R&D department,
micro PLCs offer a hands-on learning experience that inspires innovation and out-of-
the-box thinking for engineers, technicians, and anyone interested in technology.
In addition to the PLC Starter Kit, Arduino has invested huge resources on developing
a comprehensive training program for professionals seeking the highly recognized
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 19
Arduino Certified Engineer credential: the Arduino Academy is designed to equip
participants with the skills and knowledge needed for industrial and building auto-
mation using Arduino Opta. The initiative will include different courses, developed in
collaboration with industry experts, offering hands-on experience and practical insights
into PLC programming.
“ Arduino’s vision of democratizing electronics now extends into in-
dustrial automation. With Opta we are lowering the barrier to entry
for new and additional use cases without impacting existing control
and automation solutions, while further empowering everyone to
innovate with Arduino Academy.”
– Guneet Bedi, Arduino’s Senior Vice President
and General Manager of the Americas
IN A NUTSHELL
From private homes to large-scale industrial enterprises, the Arduino Opta micro PLC
offers a nimble solution that is scalable and future-proof. Tying in with Arduino’s signa-
ture open and community-supported approach, it empowers a whole new generation
of engineers with a tool that is flexible, easy to use, and effortless to learn: lowering
barriers so anyone can be the innovator in their industry.
Ready to Try the Unconventionally Simple Path to Industrial
Automation?
In conclusion, micro PLCs like Arduino Opta represent a significant leap forward in
industrial automation technology, offering unmatched versatility and efficiency in a
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 19
Arduino Certified Engineer credential: the Arduino Academy is designed to equip
participants with the skills and knowledge needed for industrial and building auto-
mation using Arduino Opta. The initiative will include different courses, developed in
collaboration with industry experts, offering hands-on experience and practical insights
into PLC programming.
“ Arduino’s vision of democratizing electronics now extends into in-
dustrial automation. With Opta we are lowering the barrier to entry
for new and additional use cases without impacting existing control
and automation solutions, while further empowering everyone to
innovate with Arduino Academy.”
– Guneet Bedi, Arduino’s Senior Vice President
and General Manager of the Americas
IN A NUTSHELL
From private homes to large-scale industrial enterprises, the Arduino Opta micro PLC
offers a nimble solution that is scalable and future-proof. Tying in with Arduino’s signa-
ture open and community-supported approach, it empowers a whole new generation
of engineers with a tool that is flexible, easy to use, and effortless to learn: lowering
barriers so anyone can be the innovator in their industry.
Ready to Try the Unconventionally Simple Path to Industrial
Automation?
In conclusion, micro PLCs like Arduino Opta represent a significant leap forward in
industrial automation technology, offering unmatched versatility and efficiency in a
fi Back to TOC
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 20
compact and user-friendly package. As industries increasingly demand flexible and
cost-effective solutions, micro PLCs are poised to redefine the future of automation,
empowering engineers and developers to push the boundaries of what’s achievable.
What sets Opta apart is its seamless integration with the Arduino ecosystem and its
commitment to open-source principles. By choosing Arduino Opta, businesses can
unlock a world of innovation and growth while sidestepping the pitfalls of vendor
lock-in. Powerful and intuitive, Opta enables a new and unique approach to auto-
mation, where the possibilities are limitless. What’s more, Opta allows for a new and
unique approach where the number of people able to work on automation grows
almost instantly, starting from the young generation of professionals who gained
experience with Arduino as students or acquired the necessary skills to leverage the
platform with help from free online resources and a community of 33+ million users.
By lowering the barriers to access technology, Opta is leading the change, offering a
more accessible and versatile platform for entry-level applications, education, proto-
typing, and IoT integration.
Whether you’re looking to streamline your production processes, enhance your build-
ing automation systems, or explore the potential of IoT integration, Opta offers a solu-
tion tailored to your needs.
Contact the Arduino team today to learn more about Opta and take the first step
toward unlocking the full potential of your automation systems.
The Micro PLC Advantage: Arduino
®
Opta
®
Redefines Industrial Automation 20
compact and user-friendly package. As industries increasingly demand flexible and
cost-effective solutions, micro PLCs are poised to redefine the future of automation,
empowering engineers and developers to push the boundaries of what’s achievable.
What sets Opta apart is its seamless integration with the Arduino ecosystem and its
commitment to open-source principles. By choosing Arduino Opta, businesses can
unlock a world of innovation and growth while sidestepping the pitfalls of vendor
lock-in. Powerful and intuitive, Opta enables a new and unique approach to auto-
mation, where the possibilities are limitless. What’s more, Opta allows for a new and
unique approach where the number of people able to work on automation grows
almost instantly, starting from the young generation of professionals who gained
experience with Arduino as students or acquired the necessary skills to leverage the
platform with help from free online resources and a community of 33+ million users.
By lowering the barriers to access technology, Opta is leading the change, offering a
more accessible and versatile platform for entry-level applications, education, proto-
typing, and IoT integration.
Whether you’re looking to streamline your production processes, enhance your build-
ing automation systems, or explore the potential of IoT integration, Opta offers a solu-
tion tailored to your needs.
Contact the Arduino team today to learn more about Opta and take the first step
toward unlocking the full potential of your automation systems.
fi Back to TOC 21
How to reduce workload using
reusable components for PLCs
Multiple programmable logic controller (PLC) platforms now support pre-
packaged code to reduce your programming time.
W
riting programmable logic controller (PLC) programs from scratch is usually
time-consuming and tedious. Many know about the long-term costs and frustra-
tions of debugging and maintaining code, but there is a method to increase the code’s
dependability and quality while streamlining and simplifying the PLC programming
process. Multiple PLC platforms can now use pre-packaged code to reduce your pro-
gramming time and support.
Three benefits of pre-packaged code
Pre-packaged code is a collection of pre-made libraries and functions that let users
quickly construct PLC applications. Pre-packaged code can help users to:
1. Accelerate your code: Using tested pre-packaged code to perform common
tasks reduces the time spent writing code. Due to this, the code may become
more responsive, resilient and faster. Users also are minimizing errors by using
proven and validated code. This reduces testing and troubleshooting time.
2. Standardize your code: Pre-packaged code can be used across different hard-
ware platforms and projects. Users can use the same functions and libraries for
different projects and follow identical coding conventions and best practices.
Using this can make the code more readable, consistent and more accessible for
others to support.
How to reduce workload using
reusable components for PLCs
Multiple programmable logic controller (PLC) platforms now support pre-
packaged code to reduce your programming time.
W
riting programmable logic controller (PLC) programs from scratch is usually
time-consuming and tedious. Many know about the long-term costs and frustra-
tions of debugging and maintaining code, but there is a method to increase the code’s
dependability and quality while streamlining and simplifying the PLC programming
process. Multiple PLC platforms can now use pre-packaged code to reduce your pro-
gramming time and support.
Three benefits of pre-packaged code
Pre-packaged code is a collection of pre-made libraries and functions that let users
quickly construct PLC applications. Pre-packaged code can help users to:
1. Accelerate your code: Using tested pre-packaged code to perform common
tasks reduces the time spent writing code. Due to this, the code may become
more responsive, resilient and faster. Users also are minimizing errors by using
proven and validated code. This reduces testing and troubleshooting time.
2. Standardize your code: Pre-packaged code can be used across different hard-
ware platforms and projects. Users can use the same functions and libraries for
different projects and follow identical coding conventions and best practices.
Using this can make the code more readable, consistent and more accessible for
others to support.
fl Back to TOC
How to reduce workload using reusable components for PLCs 22
3. Reduce support costs: Using pre-packaged code, users can update or replace
these packages when needed. For example, if a machine uses pre-packaged
code that interacts with an outside platform, users can update the package with-
out redoing the code if it updates its communication spec.
CODESYS is a programming software that works with multiple PLCs. In the CODESYS,
pre-packaged code is available in the form of libraries. Users can download many free
libraries, but some have a cost or only work with specific hardware. To use pre-pack-
aged code in CODESYS, users need to follow a few simple steps.
1. Identify the library that contains the code you need.
2. Import the library into your project.
3. Write the code to interact with the library.
For example, there was a case where message queuing telemetry transport (MQTT)
messaging to an existing PLC program. While MQTT is a feature not native to this par-
ticular PLC, CODESYS has several different library options, including ones that support
Sparkplug B.
For this application creation, WagoAppCloud library and the Native MQTT support it
offers were used to send messages to the MQTT broker.
Another example would be adding SQL database connectivity, which is not a feature
that comes with the PLC. There are multiple libraries that can connect to a database.
How to reduce workload using reusable components for PLCs 22
3. Reduce support costs: Using pre-packaged code, users can update or replace
these packages when needed. For example, if a machine uses pre-packaged
code that interacts with an outside platform, users can update the package with-
out redoing the code if it updates its communication spec.
CODESYS is a programming software that works with multiple PLCs. In the CODESYS,
pre-packaged code is available in the form of libraries. Users can download many free
libraries, but some have a cost or only work with specific hardware. To use pre-pack-
aged code in CODESYS, users need to follow a few simple steps.
1. Identify the library that contains the code you need.
2. Import the library into your project.
3. Write the code to interact with the library.
For example, there was a case where message queuing telemetry transport (MQTT)
messaging to an existing PLC program. While MQTT is a feature not native to this par-
ticular PLC, CODESYS has several different library options, including ones that support
Sparkplug B.
For this application creation, WagoAppCloud library and the Native MQTT support it
offers were used to send messages to the MQTT broker.
Another example would be adding SQL database connectivity, which is not a feature
that comes with the PLC. There are multiple libraries that can connect to a database.
fi Back to TOC
How to reduce workload using reusable components for PLCs 23
In this case, it was the
Microsoft SQL data-
base and used the
WagoAPPSQL_MsSQL
library. This hard-
ware-specific library al-
lows users to connect
and send SQL syntax
to a database.
Using pre-packaged
code can help reduce
programming time
and support efforts
and improve workflow
and development
time. Users also can
benefit from the advantages of pre-packaged code
and create better PLC programs faster and easier. Us-
ers might be surprised how pre-packaged code can
improve their next project.
Brandon Teachman
Brandon Teachman is an application engineer at Vision Control & Automation, where he
helps businesses improve their manufacturing processes through automation solutions.
Figure 1: The Library Manager in
CODESYS that allows users to add and
select pre-packaged code for a project.
Courtesy: Vision Control & Automation
How to reduce workload using reusable components for PLCs 23
In this case, it was the
Microsoft SQL data-
base and used the
WagoAPPSQL_MsSQL
library. This hard-
ware-specific library al-
lows users to connect
and send SQL syntax
to a database.
Using pre-packaged
code can help reduce
programming time
and support efforts
and improve workflow
and development
time. Users also can
benefit from the advantages of pre-packaged code
and create better PLC programs faster and easier. Us-
ers might be surprised how pre-packaged code can
improve their next project.
Brandon Teachman
Brandon Teachman is an application engineer at Vision Control & Automation, where he
helps businesses improve their manufacturing processes through automation solutions.
Figure 1: The Library Manager in
CODESYS that allows users to add and
select pre-packaged code for a project.
Courtesy: Vision Control & Automation
Back to TOC
The Do-more BRX PLC from
AutomationDirect
Introducing the BEST budget PLC, the newest family of Do-more
PLCs - The BRX. You asked for it: Feature packed, Low Price.
Making it the perfect Budget PLC or the Any budget PLC. This
affordable PLC can do it all, from a small budget PLC all the way
to a large scale installation. This new family gives the best low
cost PLC, without having to settle for less.
The Do-more BRX PLC from AutomationDirect 24
The Do-more BRX PLC from
AutomationDirect
Introducing the BEST budget PLC, the newest family of Do-more
PLCs - The BRX. You asked for it: Feature packed, Low Price.
Making it the perfect Budget PLC or the Any budget PLC. This
affordable PLC can do it all, from a small budget PLC all the way
to a large scale installation. This new family gives the best low
cost PLC, without having to settle for less.
The Do-more BRX PLC from AutomationDirect 24
fi Back to TOC 25
See the future: Four benefits of
software-defined industrial controls
Modern automation solutions are already untethering the control system from
its hardware constraints, enabling operations teams to drive more flexible
projects and operations. See four benefits of software-defined control systems.
T
oday’s process and hybrid manufacturers face a different set of challenges than
they did five or ten years ago, and software-defined control systems are helping.
Companies are making commitments to increase sustainability, even going so far as to
set net zero goals to be reached within the next few years. Simultaneously, a dynam-
ic global marketplace has forced manufacturers to be more flexible to meet the ev-
er-shifting needs of their customers.
To accomplish these goals, companies need easy access to data, a journey they are
undertaking by evolving toward a vision of boundless automation, where data moves
seamlessly from the intelligent field, through the edge and into the cloud. Teams need
easy access to data to drive the productivity and operational agility that will help them
meet their goals, but legacy control technologies are more likely to silo data than to
free data use. This disparity is prompting many operations teams to consider new proj-
ects to replace their aging infrastructure, but traditional expansion and modernization
projects can be complex and expensive.
Software-defined control technology is a model that will ultimately make projects eas-
ier to execute and more cost-effective by eliminating built-for-purpose control hard-
ware for more flexible, scalable, future-proofed operations. Consequently, understand-
ing software-defined control will be essential to navigating the future of automation.
See the future: Four benefits of
software-defined industrial controls
Modern automation solutions are already untethering the control system from
its hardware constraints, enabling operations teams to drive more flexible
projects and operations. See four benefits of software-defined control systems.
T
oday’s process and hybrid manufacturers face a different set of challenges than
they did five or ten years ago, and software-defined control systems are helping.
Companies are making commitments to increase sustainability, even going so far as to
set net zero goals to be reached within the next few years. Simultaneously, a dynam-
ic global marketplace has forced manufacturers to be more flexible to meet the ev-
er-shifting needs of their customers.
To accomplish these goals, companies need easy access to data, a journey they are
undertaking by evolving toward a vision of boundless automation, where data moves
seamlessly from the intelligent field, through the edge and into the cloud. Teams need
easy access to data to drive the productivity and operational agility that will help them
meet their goals, but legacy control technologies are more likely to silo data than to
free data use. This disparity is prompting many operations teams to consider new proj-
ects to replace their aging infrastructure, but traditional expansion and modernization
projects can be complex and expensive.
Software-defined control technology is a model that will ultimately make projects eas-
ier to execute and more cost-effective by eliminating built-for-purpose control hard-
ware for more flexible, scalable, future-proofed operations. Consequently, understand-
ing software-defined control will be essential to navigating the future of automation.
fl Back to TOC
See the future: Four benefits of software-defined industrial controls 26
Why software-defined control for industrial control systems?
Today, when an operations team wants to expand or modernize its automation system,
it typically must purchase and install a variety of new hardware components. Often the
team needs to purchase specific industrial hardware controllers, and then house them
in built-for-purpose cabinets. They also purchase the new I/O necessary to run opera-
tions, and they need a network layer to accommodate all the new equipment.
Software-defined control will eliminate the hardware complexity of existing automation
systems. Instead of built-for-purpose hardware, teams should be able to execute con-
tainerized control workloads on many different hardware platforms. One likely deploy-
ment environment for software-defined workloads is delivered via hyperconverged
infrastructure (HCI), with the control system operating as a redundant service on an
HCI environment (Figure 1).
Figure 1: Hyperconverged infrastructure (HCI) is a building block of the software-defined platform,
combining traditional and real-time workloads. Emerson’s Boundless Automation vision is
software-defined control technology, a model designed to make projects easier to execute and
more cost-effective by eliminating built-for-purpose control hardware for more flexible, scalable,
future-proofed operations. Courtesy: Emerson
See the future: Four benefits of software-defined industrial controls 26
Why software-defined control for industrial control systems?
Today, when an operations team wants to expand or modernize its automation system,
it typically must purchase and install a variety of new hardware components. Often the
team needs to purchase specific industrial hardware controllers, and then house them
in built-for-purpose cabinets. They also purchase the new I/O necessary to run opera-
tions, and they need a network layer to accommodate all the new equipment.
Software-defined control will eliminate the hardware complexity of existing automation
systems. Instead of built-for-purpose hardware, teams should be able to execute con-
tainerized control workloads on many different hardware platforms. One likely deploy-
ment environment for software-defined workloads is delivered via hyperconverged
infrastructure (HCI), with the control system operating as a redundant service on an
HCI environment (Figure 1).
Figure 1: Hyperconverged infrastructure (HCI) is a building block of the software-defined platform,
combining traditional and real-time workloads. Emerson’s Boundless Automation vision is
software-defined control technology, a model designed to make projects easier to execute and
more cost-effective by eliminating built-for-purpose control hardware for more flexible, scalable,
future-proofed operations. Courtesy: Emerson
fl Back to TOC
See the future: Four benefits of software-defined industrial controls 27
Four benefits of software-defined control systems for
industrial control
The software-defined model for control will offer four key benefits:
1. Resiliency: The high-availability redundant control today’s operations demand
will be further With multiple controllers running simultaneously on HCI, teams
will be able to add additional automation workloads without facility shutdowns.
Extending or adding automation will simply require deploying lightweight con-
tainerized control functions in the virtualized environment, developing the in-
put-output (I/O) subsystem in the expansion area, and then auto sensing the field
devices in the automation system. And if one containerized control function fails,
HCI’s rapid failover features will empower the team to keep operating continu-
ously and seamlessly. The flexibility provided by HCI allows for fault tolerance
beyond the traditional 1:1 primary/backup architecture, including the potential to
fail over to virtualized hosts in another physical location.
2. Scalability: The adaptability of control systems will fundamentally change when
operations can add capacity without a complex hardware system redesign. Gone
are the days of designing and setting up more cabinets for additional control
With HCI, adding additional computing power is as simple as connecting another
blade in a server cabinet.
3. Flexibility: Software-defined control simplifies project execution and ongoing
operations. Instead of needing to calculate every device signal tag (DST) when
expanding or modernizing operations, teams can safely estimate their require-
ments and adjust as needed. If the project team needs to make changes at any
See the future: Four benefits of software-defined industrial controls 27
Four benefits of software-defined control systems for
industrial control
The software-defined model for control will offer four key benefits:
1. Resiliency: The high-availability redundant control today’s operations demand
will be further With multiple controllers running simultaneously on HCI, teams
will be able to add additional automation workloads without facility shutdowns.
Extending or adding automation will simply require deploying lightweight con-
tainerized control functions in the virtualized environment, developing the in-
put-output (I/O) subsystem in the expansion area, and then auto sensing the field
devices in the automation system. And if one containerized control function fails,
HCI’s rapid failover features will empower the team to keep operating continu-
ously and seamlessly. The flexibility provided by HCI allows for fault tolerance
beyond the traditional 1:1 primary/backup architecture, including the potential to
fail over to virtualized hosts in another physical location.
2. Scalability: The adaptability of control systems will fundamentally change when
operations can add capacity without a complex hardware system redesign. Gone
are the days of designing and setting up more cabinets for additional control
With HCI, adding additional computing power is as simple as connecting another
blade in a server cabinet.
3. Flexibility: Software-defined control simplifies project execution and ongoing
operations. Instead of needing to calculate every device signal tag (DST) when
expanding or modernizing operations, teams can safely estimate their require-
ments and adjust as needed. If the project team needs to make changes at any
fi Back to TOC
See the future: Four beneflts of software-deflned industrial controls 28
time that impact the capacity or type of I/O points, scaling the DSTs up or down
simply requires a change in the software configuration. Teams are no longer limit-
ed by the decisions made in project execution, instead growing their automation
alongside their operational needs.
4. Extensibility: Automation technology changes frequently. While teams would
often like to take advantage of the new features available in control system up-
dates, it can be difficult to do so when updates require production outages. Soft-
ware-defined control will simplify the process. As new features are released by
automation suppliers, operations teams using software-defined systems can up-
date and change control software and strategies without interrupting production,
updating one control function instance while its primary continues operations.
Why is the software-defined control transition happening now?
The technology building blocks to support software-defined control have been avail-
able for years, but automation users and suppliers are just beginning the journey to
adapt their environments to use that technology. This shift has come just as new tech-
nologies in the field, such as Ethernet Advanced Physical Layer (Ethernet APL), are
unlocking new data sources that will push current control hardware to (or beyond) its
limits. Massive amounts of data will soon be coming into the control system from the
intelligent field, including video, acoustic monitoring, and other areas. The most inno-
vative companies are identifying ways to integrate that data into control strategies.
Eventually, every company will need a future-proofed architecture to ingest the expo-
nential increase of data that will come from the intelligent field. Moving toward that
future today will help teams ensure they are on a path to an automation platform that
enables industry-leading operational performance (Figure 2).
See the future: Four beneflts of software-deflned industrial controls 28
time that impact the capacity or type of I/O points, scaling the DSTs up or down
simply requires a change in the software configuration. Teams are no longer limit-
ed by the decisions made in project execution, instead growing their automation
alongside their operational needs.
4. Extensibility: Automation technology changes frequently. While teams would
often like to take advantage of the new features available in control system up-
dates, it can be difficult to do so when updates require production outages. Soft-
ware-defined control will simplify the process. As new features are released by
automation suppliers, operations teams using software-defined systems can up-
date and change control software and strategies without interrupting production,
updating one control function instance while its primary continues operations.
Why is the software-defined control transition happening now?
The technology building blocks to support software-defined control have been avail-
able for years, but automation users and suppliers are just beginning the journey to
adapt their environments to use that technology. This shift has come just as new tech-
nologies in the field, such as Ethernet Advanced Physical Layer (Ethernet APL), are
unlocking new data sources that will push current control hardware to (or beyond) its
limits. Massive amounts of data will soon be coming into the control system from the
intelligent field, including video, acoustic monitoring, and other areas. The most inno-
vative companies are identifying ways to integrate that data into control strategies.
Eventually, every company will need a future-proofed architecture to ingest the expo-
nential increase of data that will come from the intelligent field. Moving toward that
future today will help teams ensure they are on a path to an automation platform that
enables industry-leading operational performance (Figure 2).
fl Back to TOC
See the future: Four benefits of software-defined industrial controls 29
Where is soft-
ware-defined con-
trol technology
today for industri-
al use?
The most advanced au-
tomation providers are
already delivering on
the earliest stages of the
software-defined control
vision. These companies
are laying the ground-
work with next-generation
virtualization built on HCI,
and they are comple-
menting that innovation
with more flexible control-
ler technology.
The most flexible control-
lers today, though still driv-
en by purpose-built hard-
ware, incorporate many of
the core concepts of soft-
ware-defined control, such
as flexible capacity to scale
the #1 value in automation
Order Today, Ships Fast!
* See our Web site for details and restrictions. © Copyright 2024 AutomationDirect, Cumming, GA USA. All rights reserved.1-800-633-0405
Cutting EDGE control you can
actually afford
Embedded Web Server
With BRX’s embedded Web server, you can
instantly access system status, diagnostic
information, and monitor memory usage from
any Internet-ready device.
Research, price, buy at:
www.BRXPLC.com
Must-have IIoT Protocols
With the growing number of IIoT platforms and
cloud computing services, BRX controllers utilize
the industry-standard MQTT(S) and FTP protocols
to seamlessly integrate with asset management/
IIoT platforms including:
• Microsoft Azure®
• IBM Watson®
Rest API
The integrated Rest API and secure HTTPS
protocol allow BRX to work with fl ow control
tools like Node-RED® in order to supply high-level
IT systems with the plant-fl oor data they need.
Starting at only $205.00
The BRX PLC has advanced features that allow it to easily take
on the role of an edge computing device - gathering, ref ning,
and delivering control system data to upstream IT collection
and BIG DATA analysis programs.
devicecatalog.azure.com
--| |---| |---( )
--| |---| |---( )
Intelligent Code Execution
With robust task management and
a variety of interrupt styles for task
prioritization.
Extensive Instruction Set
Discrete, process, and multi-axis
motion control instructions to
support even complex applications,
executed with familiar ladder logic
programming.
Powerful Math Functions
Enabling scripted math and algebra,
to support rich data pre-processing
right at the edge.
2406-DesignWorld-BRXPLCs-MAG.indd 12406-DesignWorld-BRXPLCs-MAG.indd 1 4/29/2024 2:11:22 PM4/29/2024 2:11:22 PM
See the future: Four benefits of software-defined industrial controls 29
Where is soft-
ware-defined con-
trol technology
today for industri-
al use?
The most advanced au-
tomation providers are
already delivering on
the earliest stages of the
software-defined control
vision. These companies
are laying the ground-
work with next-generation
virtualization built on HCI,
and they are comple-
menting that innovation
with more flexible control-
ler technology.
The most flexible control-
lers today, though still driv-
en by purpose-built hard-
ware, incorporate many of
the core concepts of soft-
ware-defined control, such
as flexible capacity to scale
the #1 value in automation
Order Today, Ships Fast!
* See our Web site for details and restrictions. © Copyright 2024 AutomationDirect, Cumming, GA USA. All rights reserved.1-800-633-0405
Cutting EDGE control you can
actually afford
Embedded Web Server
With BRX’s embedded Web server, you can
instantly access system status, diagnostic
information, and monitor memory usage from
any Internet-ready device.
Research, price, buy at:
www.BRXPLC.com
Must-have IIoT Protocols
With the growing number of IIoT platforms and
cloud computing services, BRX controllers utilize
the industry-standard MQTT(S) and FTP protocols
to seamlessly integrate with asset management/
IIoT platforms including:
• Microsoft Azure®
• IBM Watson®
Rest API
The integrated Rest API and secure HTTPS
protocol allow BRX to work with fl ow control
tools like Node-RED® in order to supply high-level
IT systems with the plant-fl oor data they need.
Starting at only $205.00
The BRX PLC has advanced features that allow it to easily take
on the role of an edge computing device - gathering, ref ning,
and delivering control system data to upstream IT collection
and BIG DATA analysis programs.
devicecatalog.azure.com
--| |---| |---( )
--| |---| |---( )
Intelligent Code Execution
With robust task management and
a variety of interrupt styles for task
prioritization.
Extensive Instruction Set
Discrete, process, and multi-axis
motion control instructions to
support even complex applications,
executed with familiar ladder logic
programming.
Powerful Math Functions
Enabling scripted math and algebra,
to support rich data pre-processing
right at the edge.
2406-DesignWorld-BRXPLCs-MAG.indd 12406-DesignWorld-BRXPLCs-MAG.indd 1 4/29/2024 2:11:22 PM4/29/2024 2:11:22 PM
fi Back to TOC
See the future: Four beneflts of software-deflned industrial controls 30
up or down based on
operating requirements.
These technologies are
the foundation driving and
supporting the future of
software-defined control.
Forward-thinking process
and hybrid manufacturers are already
integrating them into projects to pre-
pare for a software-defined future.
Less industrial control
system hardware, more control over resiliency, scalability,
flexibility, extensibility
As more organizations embrace a vision of boundless automation for enhanced data
mobility, the future of control will change rapidly. New control systems will be built on
flexibility and software-defined solutions are a foundational element of that path for-
ward. Manufacturers have long asked for automation solutions empowering them to
pay only for what they need, when they need it. Software-defined control will put that
power into their hands, and the earliest steps on that path can already be taken today.
Sean Saul
Sean Saul is the vice president of the DeltaV Platform at Emerson, where he is re-
sponsible for leading the overall product direction for the DeltaV Distributed Control
System and Safety Instrumented System platforms. Saul holds a bachelor’s degree in
electrical engineering from the University of Texas at Dallas and a master’s degree in
business administration from the University of Texas at Austin.
Figure 2: As new, more complex, and more bandwidth-
intensive data sources are added from inside and outside the
enterprise, organizations will need an infrastructure to support
the next-gen intelligent field, along with external sources of
data, such as commodity prices. Courtesy: Emerson
See the future: Four beneflts of software-deflned industrial controls 30
up or down based on
operating requirements.
These technologies are
the foundation driving and
supporting the future of
software-defined control.
Forward-thinking process
and hybrid manufacturers are already
integrating them into projects to pre-
pare for a software-defined future.
Less industrial control
system hardware, more control over resiliency, scalability,
flexibility, extensibility
As more organizations embrace a vision of boundless automation for enhanced data
mobility, the future of control will change rapidly. New control systems will be built on
flexibility and software-defined solutions are a foundational element of that path for-
ward. Manufacturers have long asked for automation solutions empowering them to
pay only for what they need, when they need it. Software-defined control will put that
power into their hands, and the earliest steps on that path can already be taken today.
Sean Saul
Sean Saul is the vice president of the DeltaV Platform at Emerson, where he is re-
sponsible for leading the overall product direction for the DeltaV Distributed Control
System and Safety Instrumented System platforms. Saul holds a bachelor’s degree in
electrical engineering from the University of Texas at Dallas and a master’s degree in
business administration from the University of Texas at Austin.
Figure 2: As new, more complex, and more bandwidth-
intensive data sources are added from inside and outside the
enterprise, organizations will need an infrastructure to support
the next-gen intelligent field, along with external sources of
data, such as commodity prices. Courtesy: Emerson
* Save 10-20% over CM5, 4”, 6”, 7”, 8”, 10”, 12”, 15”
* Same cut-out as CM5/EA9
(C-more copied from EZTouch in 2005)
* Communicates to over 95% of PLCs
* Free application support including weekends
* 30 day money back guarantee
* Free program conversion for orders over $4000
* More Bright - 400NITs @ 55°C , Longer Life 75K hrs
C-MORE - NO MORE
Same day FREE SHIPPING if Ordered by 6 p.m. CST
16 Reasons to choose EZ5 over C-More:
EZTouch Since 2001
Top of the Line Features with QS900 Automotive Quality.
Made in China
*
Save Costs, get better
product and Support
American Families and
Jobs at the same time!
*
EZ5 HMI
Made in America HMIs
That cost less than Made in China
Save up to 19.2% over CM5 C-more
(table inside)
EZ5 7” - $399, EZ5 10.4” - $699, EZ5 15” - $1299
Stable Prices, No Supply Chain Issues,
No Tariffs
Call or text Application Hotline at 563-726-1359
* The Incredible HC Module - 8 DC outputs, Short Circuit Proof
capable of handling 4amp in rush current and 1 amp steady state
current in an incredible 2” x 2” x 1” plug in module
2 USB, 2 Serial
1 HMI Ethernet
1 Micro SD
* PLC Ethernet optional
* HMI DH+ optional 8 pt. I/O
Digital $34
Analog 12bit $159
7” EZTouchPLC
$699 + I/O
4, 1 form C Relay outputs,
5 Amp, 250 VAC, LED indicator
12 Digital
inputs sink
or source,
dual color
LED
Plug-in
removable
terminal
blocks
8 Digital sourcing outputs,
50 V, 500 mA, short circuit
proof LED indicator
2 Analog Voltage
In, 0-10V, 12 bit
2 Analog Voltage
Out, 0-10V, 12 bit
3.5” TFT LED
display, 400 nits,
75k hrs.
EZminiTouchPLC, an Engineering Marvel
like nothing else in this world!
Here’s what you get?
• 3.5” or 6” TFT LED disply, 400 nits, 75k hrs.
• 12 Digital inputs sink or source, dual color LED
• 8 DC outputs, 50V, 500mA, short circuit proof
LED indicator
• 4, 1 form C Relay outputs, 5Amp
• 2 Analog In • 2 Analog Out
• 1 Serial port • Ethernet Optional
• Plug-in removable terminal blocks
• Patented Online Edit
• 55 High End Instruction Set w/function blocks
• Great Graphics and Animations
• On Screen Recipe Edit • Datalogging
• miniWifi option available to be able to
program 50ft away with cable ($59)
• Remote monitoring and control over PC
or Smartphone
EZTouchPLC Especially Designed for OEMs and
System Integrators to save panel space and cost
Uniquely AmericanOnly HMI w. Fully Modular PLC I/O
6”, 7”, 8”, 10”, 12”,15” Displays and
32 or 64 of Cube I/Os
(Soon to Double)
* High End HMI with Data Logging
* High PLC with 55 Instructions,
Great Function Blocks, PID & Math
* Super Fast Response Time down to 100µs
* 33 Different Plug-in I/O combo modules
with status LED for each digital I/O
* Simplest Integrated Programming Software bar none, just $149
* Sunlight readable 6” and 10 “ models
* Remote monitoring and control over PC or Smartphone
*All Models available with miniWifi option ($59) to be able to program 50ft away w/o cable $349
4” Display
Email to [email protected]
https://www.EZAutomation.net/TouchPLC
EZAutomation.net/miniTouchPLC
7” w/32 I/O 8.05x6.15x4.37”, 10” w/64 I/O 13.58x10.5x4.51” (I/O soon to double)
5.06x4.08x1.5”
* Same cut-out as CM5/EA9
(C-more copied from EZTouch in 2005)
* Communicates to over 95% of PLCs
* Free application support including weekends
* 30 day money back guarantee
* Free program conversion for orders over $4000
* More Bright - 400NITs @ 55°C , Longer Life 75K hrs
C-MORE - NO MORE
Same day FREE SHIPPING if Ordered by 6 p.m. CST
16 Reasons to choose EZ5 over C-More:
EZTouch Since 2001
Top of the Line Features with QS900 Automotive Quality.
Made in China
*
Save Costs, get better
product and Support
American Families and
Jobs at the same time!
*
EZ5 HMI
Made in America HMIs
That cost less than Made in China
Save up to 19.2% over CM5 C-more
(table inside)
EZ5 7” - $399, EZ5 10.4” - $699, EZ5 15” - $1299
Stable Prices, No Supply Chain Issues,
No Tariffs
Call or text Application Hotline at 563-726-1359
* The Incredible HC Module - 8 DC outputs, Short Circuit Proof
capable of handling 4amp in rush current and 1 amp steady state
current in an incredible 2” x 2” x 1” plug in module
2 USB, 2 Serial
1 HMI Ethernet
1 Micro SD
* PLC Ethernet optional
* HMI DH+ optional 8 pt. I/O
Digital $34
Analog 12bit $159
7” EZTouchPLC
$699 + I/O
4, 1 form C Relay outputs,
5 Amp, 250 VAC, LED indicator
12 Digital
inputs sink
or source,
dual color
LED
Plug-in
removable
terminal
blocks
8 Digital sourcing outputs,
50 V, 500 mA, short circuit
proof LED indicator
2 Analog Voltage
In, 0-10V, 12 bit
2 Analog Voltage
Out, 0-10V, 12 bit
3.5” TFT LED
display, 400 nits,
75k hrs.
EZminiTouchPLC, an Engineering Marvel
like nothing else in this world!
Here’s what you get?
• 3.5” or 6” TFT LED disply, 400 nits, 75k hrs.
• 12 Digital inputs sink or source, dual color LED
• 8 DC outputs, 50V, 500mA, short circuit proof
LED indicator
• 4, 1 form C Relay outputs, 5Amp
• 2 Analog In • 2 Analog Out
• 1 Serial port • Ethernet Optional
• Plug-in removable terminal blocks
• Patented Online Edit
• 55 High End Instruction Set w/function blocks
• Great Graphics and Animations
• On Screen Recipe Edit • Datalogging
• miniWifi option available to be able to
program 50ft away with cable ($59)
• Remote monitoring and control over PC
or Smartphone
EZTouchPLC Especially Designed for OEMs and
System Integrators to save panel space and cost
Uniquely AmericanOnly HMI w. Fully Modular PLC I/O
6”, 7”, 8”, 10”, 12”,15” Displays and
32 or 64 of Cube I/Os
(Soon to Double)
* High End HMI with Data Logging
* High PLC with 55 Instructions,
Great Function Blocks, PID & Math
* Super Fast Response Time down to 100µs
* 33 Different Plug-in I/O combo modules
with status LED for each digital I/O
* Simplest Integrated Programming Software bar none, just $149
* Sunlight readable 6” and 10 “ models
* Remote monitoring and control over PC or Smartphone
*All Models available with miniWifi option ($59) to be able to program 50ft away w/o cable $349
4” Display
Email to [email protected]
https://www.EZAutomation.net/TouchPLC
EZAutomation.net/miniTouchPLC
7” w/32 I/O 8.05x6.15x4.37”, 10” w/64 I/O 13.58x10.5x4.51” (I/O soon to double)
5.06x4.08x1.5”
1. Stable predictable prices without tariff
uncertainty
America is waking up to the threats of Made in China
poses. It was first brought to light by President Trump
when he imposed import tariffs of 25% or more in 2018.
However, the tariffs applied only to raw components im-
ported from China rather than the finished products such
as human-machine interfaces (HMIs) and programmable
logic controllers (PLCs). President Biden not only contin-
ued the Trump tariffs; he recently increased the tariffs.
Politics aside, tariffs on Made in China are here to stay
and will increase over time.
This makes the prices of Made in China unpredictable.
Stable prices of Made in America automation products
offer stable prices, is a significant benefit to American
Automation engineers, now and in the future.
With EZAutomation, you not only get stable and tar-
iff free prices, you get Made in America products that
cost less than Made in China. EZTouch EZ3-EE HMIs
Nine benefits
of using Made
in America
automation
products for
OEMs
Buying products from manufacturers that operate
in America offer several benefits to original
equipment manufacturers (OEMs). See nine ways
OEMs can benefit.
uncertainty
America is waking up to the threats of Made in China
poses. It was first brought to light by President Trump
when he imposed import tariffs of 25% or more in 2018.
However, the tariffs applied only to raw components im-
ported from China rather than the finished products such
as human-machine interfaces (HMIs) and programmable
logic controllers (PLCs). President Biden not only contin-
ued the Trump tariffs; he recently increased the tariffs.
Politics aside, tariffs on Made in China are here to stay
and will increase over time.
This makes the prices of Made in China unpredictable.
Stable prices of Made in America automation products
offer stable prices, is a significant benefit to American
Automation engineers, now and in the future.
With EZAutomation, you not only get stable and tar-
iff free prices, you get Made in America products that
cost less than Made in China. EZTouch EZ3-EE HMIs
Nine benefits
of using Made
in America
automation
products for
OEMs
Buying products from manufacturers that operate
in America offer several benefits to original
equipment manufacturers (OEMs). See nine ways
OEMs can benefit.
fl Back to TOC
Nine benefits of using Made in America automation products for OEMs 33
cost less than EA9 C-more from Automationdirect, EZTouch EZ5 HMIs cost less
than CM5 from Automationdirect, and EZTouchPLCs cost less than their PLCs.
2. Stable and faster delivery with supply chain issues minimized
We all remember supply chain disruption starting with the COVID-19 pandemic in
2020. In the next three years, lead time for automation products from China went to as
much as 26 weeks. Transportation costs quadrupled. America had difficult time getting
the most basic necessities like penicillin. Whereas EZAutomation was also impacted
as some of its components come from China, yet the overall lead times were far better
than products from China. EZAutomation promises Same day FREE shipping for
orders placed till 6 p.m. CST (4 p.m. PST) for most of its products.
3. Better products and services resulting from shorter end user
proximity
We design and manufacture our products in the heartland of America, Iowa
and Illinois.
Example: AVG Automation has over 500 man years of plant experience and that shows
in our products. The same is not possible for products made in mass volumes in Chi-
na at low cost. EZAutomation products incorporate attention to detail resulting
from this vast plant experience, resulting in consistently decreasing down time in
EZAutomation plants. It is this driving force that results in:
a. Patented on-line Edit as a common and exclusive feature in our HMIs.
b. miniWifi that allows programs to be edited from 50 ft. away without needing a
programming cable.
Nine benefits of using Made in America automation products for OEMs 33
cost less than EA9 C-more from Automationdirect, EZTouch EZ5 HMIs cost less
than CM5 from Automationdirect, and EZTouchPLCs cost less than their PLCs.
2. Stable and faster delivery with supply chain issues minimized
We all remember supply chain disruption starting with the COVID-19 pandemic in
2020. In the next three years, lead time for automation products from China went to as
much as 26 weeks. Transportation costs quadrupled. America had difficult time getting
the most basic necessities like penicillin. Whereas EZAutomation was also impacted
as some of its components come from China, yet the overall lead times were far better
than products from China. EZAutomation promises Same day FREE shipping for
orders placed till 6 p.m. CST (4 p.m. PST) for most of its products.
3. Better products and services resulting from shorter end user
proximity
We design and manufacture our products in the heartland of America, Iowa
and Illinois.
Example: AVG Automation has over 500 man years of plant experience and that shows
in our products. The same is not possible for products made in mass volumes in Chi-
na at low cost. EZAutomation products incorporate attention to detail resulting
from this vast plant experience, resulting in consistently decreasing down time in
EZAutomation plants. It is this driving force that results in:
a. Patented on-line Edit as a common and exclusive feature in our HMIs.
b. miniWifi that allows programs to be edited from 50 ft. away without needing a
programming cable.
fi Back to TOC
Nine beneflts of using Made in America automation products for OEMs 34
c. OEM utility to be able to update user programs over email without any program-
ming software.
d. Plug-in PLC I/O modules.
e. Removable Plug-in terminal blocks for PLC/IO wiring.
f. LED indicator lights for all digital I/O’s.
g. Remote HMI/PLC monitoring over smart phones and internet.
h. Self-Learn EZ Programming software so simple that even your CEO can do it in
minutes.
i. P ractically 24/7 local tech/application support around the clock.
4. Products that reflect American innovation
America became a great industrial power on the back of its innovation that runs
through the blood of so many Americans. Manufacturers sitting thousands of miles
away can copy American products, but U.S. innovation remains respected the
world over. Examples include:
a. All EZTouch HMIs have a patented on-line edit feature. It is well known that on
the average, a new HMI installation requires 5 edits to its screen design in the first
three months of its use. EZAutomation by AVG is the only company that al-
lows on-line edit without shutting down or disconnecting the HMI. This saves
the End-user thousands of dollars in downtime.
Nine beneflts of using Made in America automation products for OEMs 34
c. OEM utility to be able to update user programs over email without any program-
ming software.
d. Plug-in PLC I/O modules.
e. Removable Plug-in terminal blocks for PLC/IO wiring.
f. LED indicator lights for all digital I/O’s.
g. Remote HMI/PLC monitoring over smart phones and internet.
h. Self-Learn EZ Programming software so simple that even your CEO can do it in
minutes.
i. P ractically 24/7 local tech/application support around the clock.
4. Products that reflect American innovation
America became a great industrial power on the back of its innovation that runs
through the blood of so many Americans. Manufacturers sitting thousands of miles
away can copy American products, but U.S. innovation remains respected the
world over. Examples include:
a. All EZTouch HMIs have a patented on-line edit feature. It is well known that on
the average, a new HMI installation requires 5 edits to its screen design in the first
three months of its use. EZAutomation by AVG is the only company that al-
lows on-line edit without shutting down or disconnecting the HMI. This saves
the End-user thousands of dollars in downtime.
fl Back to TOC
Nine benefits of using Made in America automation products for OEMs 35
b. Modular TouchPLC concept that is an all-in-one
HMI and PLC that can be programmed with a sin -
gle software, that saves one third of panel space and
one third of cost. There are 33 different I/O modules
that can be plugged in for an extremely flexible con-
trol system design.
c. Tiny High power HC plug-in I/O module that can handle huge in-rush cur-
rents while retaining its small size of 2”x2”x1”. All
dc solenoids or fans have a huge in-rush current. For
example a 24 Vdc 250 ma solenoid can have an inrush
current of 1.6 Amps. Normally, the control system
designer is forced to use external Relay modules to
achieve the in-rush current which takes away their
short circuit protection feature. The HC High current
dc output module for our PLCs is capable of handling 4 amp in-rush current
per module and 1 amp of steady state current for each of eight outputs,
while retaining its short circuit protection feature.
Nine benefits of using Made in America automation products for OEMs 35
b. Modular TouchPLC concept that is an all-in-one
HMI and PLC that can be programmed with a sin -
gle software, that saves one third of panel space and
one third of cost. There are 33 different I/O modules
that can be plugged in for an extremely flexible con-
trol system design.
c. Tiny High power HC plug-in I/O module that can handle huge in-rush cur-
rents while retaining its small size of 2”x2”x1”. All
dc solenoids or fans have a huge in-rush current. For
example a 24 Vdc 250 ma solenoid can have an inrush
current of 1.6 Amps. Normally, the control system
designer is forced to use external Relay modules to
achieve the in-rush current which takes away their
short circuit protection feature. The HC High current
dc output module for our PLCs is capable of handling 4 amp in-rush current
per module and 1 amp of steady state current for each of eight outputs,
while retaining its short circuit protection feature.
fl Back to TOC
Nine benefits of using Made in America automation products for OEMs 36
d. EZminiWifi: All our HMI based products have the op-
tion of turning their RS232 serial port into a miniWifi
port. Many times the HMI location is not that easy to ac-
cess. EZ miniWifi allows the controls engineer to edit
the HMI/PLC program from 50 feet away without
the need to plug a programming cable into the HMI.
In addition, the EZ miniWifi is secure as it is a point-to-
point communication channel.
e. All EZTouch HMIs have a feature called OEM Utility. This fea-
ture allows field upgrade of an HMI program over email. No
need for programming software or plugging in a USB. Person desir-
ing to upgrade the HMI program can send an executable file with
their changes and email to the field. All the user has to do is con-
nect the HMI to a computer and execute the upgrade.
f. Detachable Front EZ7: Plant, maintenance and
control engineers know the weakest component in
an HMI is the touchscreen and display as these are
subject to a lot more wear and tear as compared
to the rest of the logic and communication elec-
tronics. In solving this problem to minimize down
time due to a failed touchscreen, EZAutomation
divides the HMI into two parts, front panel with
touchscreen and display and the back pan-
el with logic and communication. If the touchscreen or display needs to be
replaced, all it takes is 2 minutes to unscrew the damaged front panel and
Nine benefits of using Made in America automation products for OEMs 36
d. EZminiWifi: All our HMI based products have the op-
tion of turning their RS232 serial port into a miniWifi
port. Many times the HMI location is not that easy to ac-
cess. EZ miniWifi allows the controls engineer to edit
the HMI/PLC program from 50 feet away without
the need to plug a programming cable into the HMI.
In addition, the EZ miniWifi is secure as it is a point-to-
point communication channel.
e. All EZTouch HMIs have a feature called OEM Utility. This fea-
ture allows field upgrade of an HMI program over email. No
need for programming software or plugging in a USB. Person desir-
ing to upgrade the HMI program can send an executable file with
their changes and email to the field. All the user has to do is con-
nect the HMI to a computer and execute the upgrade.
f. Detachable Front EZ7: Plant, maintenance and
control engineers know the weakest component in
an HMI is the touchscreen and display as these are
subject to a lot more wear and tear as compared
to the rest of the logic and communication elec-
tronics. In solving this problem to minimize down
time due to a failed touchscreen, EZAutomation
divides the HMI into two parts, front panel with
touchscreen and display and the back pan-
el with logic and communication. If the touchscreen or display needs to be
replaced, all it takes is 2 minutes to unscrew the damaged front panel and
fl Back to TOC
Nine benefits of using Made in America automation products for OEMs 37
replace it with a new one. No rewiring, no downloading HMI programming,
no HMI set-up and no extra efforts are needed to get the HMI running again.
g. EZminiTouchPLC is an engineering marvel that puts incredible processing power in
every cubic inch of this product. 4” unit, 12 DI, 8 DC 500 ma short circuit proof
outputs, 2 12 bit AIN and 2 12 bit AIO, 4 1formC 5 A relays with built in snub-
ber networks, 250 KHz encoder, serial port, Ethernet, LED indicators for all I/O,
plug-in removable terminal blocks, all packed into a 5.06×4.08×1.5” enclosure.
h. Innovating the EZMarquee: All LEDs lose their brightness as they age, making an
LED message display to lose characters in the
middle of the display. EZMarquee is man-
ufactured with pre-measured luminous
intensity so that the loss of brightness is
uniform and the message display looks like
it is fresh out of box even 10 years after the installation. In addition, the EZMar-
quees weigh one-third and consume one third the power of all competitors and
cost one-third, as well.
i. Innovating EZiMarquee: Whereas EZmarquees communicate to more than 95%
of PLCs in the market, EZAutomation came up with the concept of having the
smarts of an HMI in the marquee that allows connection to any PLC network re-
quiring no change in PLC programming. It simply monitors all the PLC tags on the
network and displays all relevant messages.
j. EZ Power Supply with LED display: When EZAutomation decided to enter the
dc power supply market, it wanted to do something different, something inno-
Nine benefits of using Made in America automation products for OEMs 37
replace it with a new one. No rewiring, no downloading HMI programming,
no HMI set-up and no extra efforts are needed to get the HMI running again.
g. EZminiTouchPLC is an engineering marvel that puts incredible processing power in
every cubic inch of this product. 4” unit, 12 DI, 8 DC 500 ma short circuit proof
outputs, 2 12 bit AIN and 2 12 bit AIO, 4 1formC 5 A relays with built in snub-
ber networks, 250 KHz encoder, serial port, Ethernet, LED indicators for all I/O,
plug-in removable terminal blocks, all packed into a 5.06×4.08×1.5” enclosure.
h. Innovating the EZMarquee: All LEDs lose their brightness as they age, making an
LED message display to lose characters in the
middle of the display. EZMarquee is man-
ufactured with pre-measured luminous
intensity so that the loss of brightness is
uniform and the message display looks like
it is fresh out of box even 10 years after the installation. In addition, the EZMar-
quees weigh one-third and consume one third the power of all competitors and
cost one-third, as well.
i. Innovating EZiMarquee: Whereas EZmarquees communicate to more than 95%
of PLCs in the market, EZAutomation came up with the concept of having the
smarts of an HMI in the marquee that allows connection to any PLC network re-
quiring no change in PLC programming. It simply monitors all the PLC tags on the
network and displays all relevant messages.
j. EZ Power Supply with LED display: When EZAutomation decided to enter the
dc power supply market, it wanted to do something different, something inno-
fi Back to TOC
Nine beneflts of using Made in America automation products for OEMs 38
vative. Result was EZPPS up to 240 W, with two LED
displays. One 3-digit voltage adjustable voltage display,
and the second, a two digit load current display. In addi-
tion, it has a maintenance timer as well as a current monitor
output that turns on if it exceeds a programmed current
limit. This is a power supply, everybody falls in love with.
k. EZ Production Monitor to improve plant productivity by 50%: EZAutomation’s
latest product introduction is a Production Mon-
itor that has a two-line 10 character each, LED
tricolor display that monitors actual production
and quality as compared to goals set for a shift.
It communicates this information to a computer over Wi-Fi up to 50 ft. away. User
interface is extremely simple: enter shift hours and goal per hour, acceptable
reject level and let the EZPM do the rest. It is bound to pay for itself within
a month. In addition, it has data logging to review past history.
5. Local American FREE Technical/Application Support,
practically 24/7
Made in America Automation products from EZAutomation have another side benefit.
Besides 6 AM to 5:30 PM CST, it has phone, text and email support for technical and
application questions. And it is FREE.
6. Local warranty and non-warranty repairs
EZAutomation Made in America products are repaired in Bettendorf, IA. Repairs are fast-
er and the analysis of a failure is faster as compared to sending the product back to
Nine beneflts of using Made in America automation products for OEMs 38
vative. Result was EZPPS up to 240 W, with two LED
displays. One 3-digit voltage adjustable voltage display,
and the second, a two digit load current display. In addi-
tion, it has a maintenance timer as well as a current monitor
output that turns on if it exceeds a programmed current
limit. This is a power supply, everybody falls in love with.
k. EZ Production Monitor to improve plant productivity by 50%: EZAutomation’s
latest product introduction is a Production Mon-
itor that has a two-line 10 character each, LED
tricolor display that monitors actual production
and quality as compared to goals set for a shift.
It communicates this information to a computer over Wi-Fi up to 50 ft. away. User
interface is extremely simple: enter shift hours and goal per hour, acceptable
reject level and let the EZPM do the rest. It is bound to pay for itself within
a month. In addition, it has data logging to review past history.
5. Local American FREE Technical/Application Support,
practically 24/7
Made in America Automation products from EZAutomation have another side benefit.
Besides 6 AM to 5:30 PM CST, it has phone, text and email support for technical and
application questions. And it is FREE.
6. Local warranty and non-warranty repairs
EZAutomation Made in America products are repaired in Bettendorf, IA. Repairs are fast-
er and the analysis of a failure is faster as compared to sending the product back to
fl Back to TOC
Nine benefits of using Made in America automation products for OEMs 39
China for failure analysis. EZAutomation has a strict 8 Discipline QS9000 policy to get to
the root cause of any product failure within warranty period in a rapid-fire succession that
allows its manufacturing lines to have a constant process improvement with local support.
7. Minimal Product Obsolescence
Another not so apparent benefit of Made in America is minimal product obsolescence.
EZAutomation/AVG still supports products introduced in 1968.
8. EZAutomation product customizer
Having all its design and manufacturing operations in Bettendorf, Iowa, EZAutomation
prides itself with a very quick response to product customization. If the products are
manufactured in volume in China, if you want a change, particularly in hardware, it will
take multiple years if the manufacturer will even entertain the idea of a customer re-
quested change. EZAutomation has designed and manufactured a significant num-
ber of customized products, such as specialty I/O modules, even when the need
is just 1000 per year, and it has done these within 3 months from concept/order
to pilot production. This is a unique benefit of Made in America.
9. Supporting American jobs and national interests
Other significant benefits of Made in America are supporting American economy, American
dollar, American standard of living, American jobs, and American national security interests.
Note: 85% of all automation products are Made in China and includes products
from major automation suppliers from the U.S., Europe and Japan.
Shalli Kumar
Shalabh “Shalli” Kumar, founder and chairman, EZAutomation
Nine benefits of using Made in America automation products for OEMs 39
China for failure analysis. EZAutomation has a strict 8 Discipline QS9000 policy to get to
the root cause of any product failure within warranty period in a rapid-fire succession that
allows its manufacturing lines to have a constant process improvement with local support.
7. Minimal Product Obsolescence
Another not so apparent benefit of Made in America is minimal product obsolescence.
EZAutomation/AVG still supports products introduced in 1968.
8. EZAutomation product customizer
Having all its design and manufacturing operations in Bettendorf, Iowa, EZAutomation
prides itself with a very quick response to product customization. If the products are
manufactured in volume in China, if you want a change, particularly in hardware, it will
take multiple years if the manufacturer will even entertain the idea of a customer re-
quested change. EZAutomation has designed and manufactured a significant num-
ber of customized products, such as specialty I/O modules, even when the need
is just 1000 per year, and it has done these within 3 months from concept/order
to pilot production. This is a unique benefit of Made in America.
9. Supporting American jobs and national interests
Other significant benefits of Made in America are supporting American economy, American
dollar, American standard of living, American jobs, and American national security interests.
Note: 85% of all automation products are Made in China and includes products
from major automation suppliers from the U.S., Europe and Japan.
Shalli Kumar
Shalabh “Shalli” Kumar, founder and chairman, EZAutomation
fi Back to TOC 40
Five vendors in an
automation distributor:
Inventory, design assistance
Five automation vendors showed a sampling of industrial automation at
DigiKey’s booth at Automate 2024 by A3, including a native CODESYS
controller, sensors, power supplies, collaborative robot and Single-Pair
Ethernet (SPE) connectors.
D
igiKey’s automation and control business provides products, experts and resourc-
es by industry, product category, manufacturer and search. Eric Wendt, director
industrial automation, DigiKey, said the company expanded into automation and con-
trols in 2016. Now automation and control industry products represent about 10% of
company sales. All products ship from a 3-million-square-foot warehouse in Minnesota,
Wendt said at the Automate 2024 event by A3, the Association for Advancing Automa-
tion, in Chicago. Why use DigiKey? Ease of use, Wendt said, providing more industrial
automation in one location than any one automation provider.
Five automation vendors were featured in the booth: Weidmuller, Omron, Siemens,
Schneider Electric and Phoenix Contact. Highlights from each follow along with links to
two related video interviews.
Weidmuller native CODESYS controller, Single-Pair
Ethernet (SPE)
At the DigiKey booth, Weidmuller showed products including a Native CODESYS Pro-
grammable Logic Controller (PLC) and Single-Pair Ethernet (SPE) Connectors.
Five vendors in an
automation distributor:
Inventory, design assistance
Five automation vendors showed a sampling of industrial automation at
DigiKey’s booth at Automate 2024 by A3, including a native CODESYS
controller, sensors, power supplies, collaborative robot and Single-Pair
Ethernet (SPE) connectors.
D
igiKey’s automation and control business provides products, experts and resourc-
es by industry, product category, manufacturer and search. Eric Wendt, director
industrial automation, DigiKey, said the company expanded into automation and con-
trols in 2016. Now automation and control industry products represent about 10% of
company sales. All products ship from a 3-million-square-foot warehouse in Minnesota,
Wendt said at the Automate 2024 event by A3, the Association for Advancing Automa-
tion, in Chicago. Why use DigiKey? Ease of use, Wendt said, providing more industrial
automation in one location than any one automation provider.
Five automation vendors were featured in the booth: Weidmuller, Omron, Siemens,
Schneider Electric and Phoenix Contact. Highlights from each follow along with links to
two related video interviews.
Weidmuller native CODESYS controller, Single-Pair
Ethernet (SPE)
At the DigiKey booth, Weidmuller showed products including a Native CODESYS Pro-
grammable Logic Controller (PLC) and Single-Pair Ethernet (SPE) Connectors.
fi Back to TOC
Five vendors in an automation distributor: Inventory, design assistance 41
The u-control WL2000 fam-
ily modular design is based
on the remote I/O system
u-remote and allows for
needs-based expansion to
include other components
from the u-mation family and
uses (along with other controllers) CODESYS software for programming. A Weidmuller
u-control starter kit (photo) is available.
The SPE field attachable plug, SPE-Plug according to IEC 63171-2, can be applied with-
out tools and has IP20 protection.
Different SPE connections are
available (photo), offering minia-
Figure 1: Weidmuller’s starter kit
for the u-control controller offers
native CODESYS programming,
as shown at the DigiKey booth at
the Automate 2024 event by A3,
the Association for Advancing
Automation, in Chicago. Courtesy:
Mark T. Hoske, Control Engineering
Figure 2: Weidmuller mounted Single-
Pair Ethernet (SPE) connector options
for comparison at the DigiKey booth
at the Automate 2024 event by A3, the
Association for Advancing Automation, in
Chicago. Courtesy: Mark T. Hoske, Control
Engineering
Five vendors in an automation distributor: Inventory, design assistance 41
The u-control WL2000 fam-
ily modular design is based
on the remote I/O system
u-remote and allows for
needs-based expansion to
include other components
from the u-mation family and
uses (along with other controllers) CODESYS software for programming. A Weidmuller
u-control starter kit (photo) is available.
The SPE field attachable plug, SPE-Plug according to IEC 63171-2, can be applied with-
out tools and has IP20 protection.
Different SPE connections are
available (photo), offering minia-
Figure 1: Weidmuller’s starter kit
for the u-control controller offers
native CODESYS programming,
as shown at the DigiKey booth at
the Automate 2024 event by A3,
the Association for Advancing
Automation, in Chicago. Courtesy:
Mark T. Hoske, Control Engineering
Figure 2: Weidmuller mounted Single-
Pair Ethernet (SPE) connector options
for comparison at the DigiKey booth
at the Automate 2024 event by A3, the
Association for Advancing Automation, in
Chicago. Courtesy: Mark T. Hoske, Control
Engineering
fi Back to TOC
Five vendors in an automation distributor: Inventory, design assistance 42
ture industrial networking connections
in standards-based form factors provid-
ing ease of use.
Omron: Sensors, IO-Link
communications
Omron sensors shown at the DigiKey
booth included presence, proxim-
ity, measurement, position, color,
fiber-optic, clear-material and time-of-
flight among others in a wide variety
of form factors, ranges, sizes, costs
and technologies, designed for var-
ious environments and applications
(photo). Color sensors, for instance,
typically have a very short range and, like
many other sensors, appropriate fixturing
and positioning is important. With IO-Link
networking capabilities, industrial sensor
communications costs have decreased.
Siemens: Power supplies, I/O block communications
Industrial automation requires controllers, communications, human-machine interfaces
(HMIs), drives and reliable power supplies, and Siemens showed a variety of options at
the DigiKey booth (photo).
Figure 3: Omron offers a wide variety of sensor
technology options for measurements across many
applications as shown at the DigiKey booth at the
Automate 2024 event by A3, the Association for
Advancing Automation, in Chicago. Courtesy: Mark
T. Hoske, Control Engineering
Five vendors in an automation distributor: Inventory, design assistance 42
ture industrial networking connections
in standards-based form factors provid-
ing ease of use.
Omron: Sensors, IO-Link
communications
Omron sensors shown at the DigiKey
booth included presence, proxim-
ity, measurement, position, color,
fiber-optic, clear-material and time-of-
flight among others in a wide variety
of form factors, ranges, sizes, costs
and technologies, designed for var-
ious environments and applications
(photo). Color sensors, for instance,
typically have a very short range and, like
many other sensors, appropriate fixturing
and positioning is important. With IO-Link
networking capabilities, industrial sensor
communications costs have decreased.
Siemens: Power supplies, I/O block communications
Industrial automation requires controllers, communications, human-machine interfaces
(HMIs), drives and reliable power supplies, and Siemens showed a variety of options at
the DigiKey booth (photo).
Figure 3: Omron offers a wide variety of sensor
technology options for measurements across many
applications as shown at the DigiKey booth at the
Automate 2024 event by A3, the Association for
Advancing Automation, in Chicago. Courtesy: Mark
T. Hoske, Control Engineering
fi Back to TOC
Five vendors in an automation distributor: Inventory, design assistance 43
Input/output devices: Sie-
mens Simatic ET200 clean
has 11 connection ports, is
made of composite plastic
for lower cost, is lightweight
and chemical resistant, with
communications including
EtherNet/IP, Modbus TCP
and Profinet.
Siemens power supplies
(photo) offer reliable offer-
ings to improve industrial
automation reliability, with
circuit breaker functionality, uninterrupt-
ible power supply options for up to two
hours of power if line power is lost. Si-
top PSU4200 options include 3-20 Amps
and IO-Link communications.
Schneider Electric: Collaborative robot
The Schneider Electric Lexium Cobot, shown at the DigiKey booth (photo), is available
in 3kg, 5kg, 7kg and 12kg payload options, with an 18kg version on the way later in
2024. SCARA, delta, cartesian robots also are available. One software is used for the
cobots, and anyone’s controller can be used. Three levels of interface are offered, in-
cluding a pendant.
Figure 4: Siemens display at the DigiKey booth at
the Automate 2024 event by A3, the Association for
Advancing Automation, in Chicago, included controllers,
drives, human-machine interface, I/O modules and power
supplies for on-machine and in-cabinet automation
use. Bottom middle are Siemens Sitop power supplies.
Courtesy: Mark T. Hoske, Control Engineering
Five vendors in an automation distributor: Inventory, design assistance 43
Input/output devices: Sie-
mens Simatic ET200 clean
has 11 connection ports, is
made of composite plastic
for lower cost, is lightweight
and chemical resistant, with
communications including
EtherNet/IP, Modbus TCP
and Profinet.
Siemens power supplies
(photo) offer reliable offer-
ings to improve industrial
automation reliability, with
circuit breaker functionality, uninterrupt-
ible power supply options for up to two
hours of power if line power is lost. Si-
top PSU4200 options include 3-20 Amps
and IO-Link communications.
Schneider Electric: Collaborative robot
The Schneider Electric Lexium Cobot, shown at the DigiKey booth (photo), is available
in 3kg, 5kg, 7kg and 12kg payload options, with an 18kg version on the way later in
2024. SCARA, delta, cartesian robots also are available. One software is used for the
cobots, and anyone’s controller can be used. Three levels of interface are offered, in-
cluding a pendant.
Figure 4: Siemens display at the DigiKey booth at
the Automate 2024 event by A3, the Association for
Advancing Automation, in Chicago, included controllers,
drives, human-machine interface, I/O modules and power
supplies for on-machine and in-cabinet automation
use. Bottom middle are Siemens Sitop power supplies.
Courtesy: Mark T. Hoske, Control Engineering
fl Back to TOC
Five vendors in an automation distributor: Inventory, design assistance 44
Phoenix Contact: Industrial net-
works, connectors, SPE
Among Phoenix Contact products at the
DigiKey booth were tool-less Push-X technol-
ogy terminal blocks, Connexis connectors,
M23 quick-turn IP67-rated connectors, shielded
M12 push-pull connectors and Single-Pair Ethernet
Connectors (photo) with IP20 and IP67 ratings.
Mark T. Hoske
Mark T. Hoske, editor-in-chief, Control Engineer-
ing, WTWH Media, [email protected],
using information collected at the DigiKey booth
and online.
Figure 5: Siemens Simatic ET200 clean I/O module has 11
connection ports, is made of composite plastic for lower cost,
is lightweight and chemical resistant, with communications
including EtherNet/IP, Modbus TCP and Profinet, as shown
at the DigiKey booth at the Automate 2024 event by A3, the
Association for Advancing Automation, in Chicago. Courtesy:
Mark T. Hoske, Control Engineering
Figure 6: The Schneider Electric Lexium Cobot, shown at the
DigiKey booth (photo), is available in 3, 5, 7 and 12kg payload
options, with an 18kg version on the way later in 2024, as shown
at the DigiKey booth at the Automate 2024 event by A3, the
Association for Advancing Automation, in Chicago. Courtesy:
Mark T. Hoske, Control Engineering
Five vendors in an automation distributor: Inventory, design assistance 44
Phoenix Contact: Industrial net-
works, connectors, SPE
Among Phoenix Contact products at the
DigiKey booth were tool-less Push-X technol-
ogy terminal blocks, Connexis connectors,
M23 quick-turn IP67-rated connectors, shielded
M12 push-pull connectors and Single-Pair Ethernet
Connectors (photo) with IP20 and IP67 ratings.
Mark T. Hoske
Mark T. Hoske, editor-in-chief, Control Engineer-
ing, WTWH Media, [email protected],
using information collected at the DigiKey booth
and online.
Figure 5: Siemens Simatic ET200 clean I/O module has 11
connection ports, is made of composite plastic for lower cost,
is lightweight and chemical resistant, with communications
including EtherNet/IP, Modbus TCP and Profinet, as shown
at the DigiKey booth at the Automate 2024 event by A3, the
Association for Advancing Automation, in Chicago. Courtesy:
Mark T. Hoske, Control Engineering
Figure 6: The Schneider Electric Lexium Cobot, shown at the
DigiKey booth (photo), is available in 3, 5, 7 and 12kg payload
options, with an 18kg version on the way later in 2024, as shown
at the DigiKey booth at the Automate 2024 event by A3, the
Association for Advancing Automation, in Chicago. Courtesy:
Mark T. Hoske, Control Engineering
H
idden leaks” are the inefficiencies and unexpected
costs that erode profitability. These leaks can take
various forms, from wasted energy due to improper pump
operation to excessive maintenance needs caused by reac-
tive, piecemeal control systems.
This article explores how a single-source solution—multi-
function PLCs, VFDs, and automation software—can plug
these leaks and optimize your pump system, to reduce
operating costs while simultaneously implementing preci-
sion control.
Below are 5 features to look for when selecting your supplier.
1. The PLCs: the Foundation for Pump
Automation
Look for PLCs that deliver the functionality needed to con-
trol pump installations, machines, and processes. PLC +
HMI controllers, with their small footprint, can be an excel-
lent choice for a crowded skid or cabinet.
Stop the Hidden
Leaks: 5 Tips for
Smart-Sourcing
Pump Automation
Controls
Is your pump control system quietly draining your
budget? One reliable supply source for all your
pump controls and automation needs—PLCs,
HMIs, I/Os, VFDs, Software, and Support—can
simplify your projects. This article tells you what
to look for when you choose a supplier.
idden leaks” are the inefficiencies and unexpected
costs that erode profitability. These leaks can take
various forms, from wasted energy due to improper pump
operation to excessive maintenance needs caused by reac-
tive, piecemeal control systems.
This article explores how a single-source solution—multi-
function PLCs, VFDs, and automation software—can plug
these leaks and optimize your pump system, to reduce
operating costs while simultaneously implementing preci-
sion control.
Below are 5 features to look for when selecting your supplier.
1. The PLCs: the Foundation for Pump
Automation
Look for PLCs that deliver the functionality needed to con-
trol pump installations, machines, and processes. PLC +
HMI controllers, with their small footprint, can be an excel-
lent choice for a crowded skid or cabinet.
Stop the Hidden
Leaks: 5 Tips for
Smart-Sourcing
Pump Automation
Controls
Is your pump control system quietly draining your
budget? One reliable supply source for all your
pump controls and automation needs—PLCs,
HMIs, I/Os, VFDs, Software, and Support—can
simplify your projects. This article tells you what
to look for when you choose a supplier.
fi Back to TOC
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 47
An example of such PLCs are Unitronics’ controllers. They are true workhorses, with con-
trollers in the field continuously automating pump applications for over two decades.
It is the unique All-in-One combination of features that have won these controllers
multiple awards in industry competitions—and that makes them particularly suitable
for pump automation and control:
• Rugged PLCs & PLC + HMI controllers: All Unitronics controllers support HMI
applications, via built-in HMI screens and/or virtual HMI. The controller’s CPU effi-
ciently runs both applications. The small footprint of All-in-One controllers makes
them excellent space-savers and eliminates PLC to HMI wiring.
• Powerful PLC features: Up to 64 auto-tuned, independent PID loops, Recipes,
Data tracing Data Tables & Data Logging, and more.
• Expandable I/Os: digital, analog, high speed, temperature, and weight measure-
ment; advanced PLCs support up to 2,048 local I/O, plus nearly limitless Ethernet
remote I/O, as well as IO-link.
• Communications: Built-in or add-on ports can be RS485/232, CANbus, Ethernet,
USB. Support is built in for a broad range of communication methods:
o Plug & play fieldbus: Ethernet/IP, EtherCAT, MODBUS, CANopen, CANlayer2,
BACnet, OCCP, HART
o A dvanced communications – OPC UA, REST API, MQTT, Web Server, GPRS,
FTP, SNMP, SQL, email, SMS, VNC, Telegram & more.
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 47
An example of such PLCs are Unitronics’ controllers. They are true workhorses, with con-
trollers in the field continuously automating pump applications for over two decades.
It is the unique All-in-One combination of features that have won these controllers
multiple awards in industry competitions—and that makes them particularly suitable
for pump automation and control:
• Rugged PLCs & PLC + HMI controllers: All Unitronics controllers support HMI
applications, via built-in HMI screens and/or virtual HMI. The controller’s CPU effi-
ciently runs both applications. The small footprint of All-in-One controllers makes
them excellent space-savers and eliminates PLC to HMI wiring.
• Powerful PLC features: Up to 64 auto-tuned, independent PID loops, Recipes,
Data tracing Data Tables & Data Logging, and more.
• Expandable I/Os: digital, analog, high speed, temperature, and weight measure-
ment; advanced PLCs support up to 2,048 local I/O, plus nearly limitless Ethernet
remote I/O, as well as IO-link.
• Communications: Built-in or add-on ports can be RS485/232, CANbus, Ethernet,
USB. Support is built in for a broad range of communication methods:
o Plug & play fieldbus: Ethernet/IP, EtherCAT, MODBUS, CANopen, CANlayer2,
BACnet, OCCP, HART
o A dvanced communications – OPC UA, REST API, MQTT, Web Server, GPRS,
FTP, SNMP, SQL, email, SMS, VNC, Telegram & more.
fl Back to TOC
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 48
• Multi-Language HMI: built-in screens range from 3.5 to 15.6” touchscreens, sup-
porting Video, Audio, & PDF files; free drag & drop graphic library included.
Unitronics controllers come in three main families: UniStream: for high-end, complex
applications, Vision for medium-sized projects, and Samba for small applications.
Note that specific features, such as the number of PID loops, type of HMI screen, ex-
pandability, etc, vary between controller models.
2. VFDs— Indispensable for Pump Applications
Ensure that your inverters provide the functionality and safety features you need; Uni-
tronics VFDs are simple to use and robust. Offering a broad power & voltage range,
available as 1 and 3-phase devices, Unitronics VFDs optimize machine performance
with integrated—and precise—torque, speed, and position closed-loop control, while
boosting safety with built-in STO.
Offering advanced motor control with features typically found in specialized drive
solutions, plus automatic integration and easy configuration, these VFDs can be used
as a standalone product or as part of an All-in-One solution with Unitronics PLC + HMI
controllers.
• Instant Integration: Automatic Setup, Communications, Commissioning—all com-
ponents work together perfectly—no communication configuration is required.
• Pre-designed HMI screens–These enable to easily—and remotely—enter the ap-
plication, commission the VFD, enter configuration parameters, and instantly start
moving.
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 48
• Multi-Language HMI: built-in screens range from 3.5 to 15.6” touchscreens, sup-
porting Video, Audio, & PDF files; free drag & drop graphic library included.
Unitronics controllers come in three main families: UniStream: for high-end, complex
applications, Vision for medium-sized projects, and Samba for small applications.
Note that specific features, such as the number of PID loops, type of HMI screen, ex-
pandability, etc, vary between controller models.
2. VFDs— Indispensable for Pump Applications
Ensure that your inverters provide the functionality and safety features you need; Uni-
tronics VFDs are simple to use and robust. Offering a broad power & voltage range,
available as 1 and 3-phase devices, Unitronics VFDs optimize machine performance
with integrated—and precise—torque, speed, and position closed-loop control, while
boosting safety with built-in STO.
Offering advanced motor control with features typically found in specialized drive
solutions, plus automatic integration and easy configuration, these VFDs can be used
as a standalone product or as part of an All-in-One solution with Unitronics PLC + HMI
controllers.
• Instant Integration: Automatic Setup, Communications, Commissioning—all com-
ponents work together perfectly—no communication configuration is required.
• Pre-designed HMI screens–These enable to easily—and remotely—enter the ap-
plication, commission the VFD, enter configuration parameters, and instantly start
moving.
fl Back to TOC
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 49
• Remote Access: you can remotely perform any task that does not require an actual
screwdriver.
3. Programming: All-in-One Free Software
Unitronics software is forever-free and provides a single, unified environment for all tasks.
• Setup, Configure, Program, and Commission All Hardware: PLCs, HMIs, AC
Servos, VFDS, and I/O in one simple environment.
• Control Application Programming: Drag & Drop Ladder, C, or Statement List; de-
velop your PLC, HMI, VFD, and Servo applications in one programming environment.
• Advanced HMI / Web Page Design: Free, full library of Drag & Drop quality im-
ages, plus colorful widgets for Trends, Gauges, and much more.
• Communications:
- Transparent communications between all Unitronics hardware components
- All industrial fieldbus and advanced protocols Simple to configure & imple-
ment
- Build your own protocol Communicate with any third-party device.
• Complex Tasks Made Easy: Auto-tuned PID, data-logging and file management
tools, Recipes, Alarms, multilanguage support, multi-level passwords and more.
• Cloud Connectivity & Notifications: Cloud services, Routers & Modems, MQTT,
SMS, Email and more.
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 49
• Remote Access: you can remotely perform any task that does not require an actual
screwdriver.
3. Programming: All-in-One Free Software
Unitronics software is forever-free and provides a single, unified environment for all tasks.
• Setup, Configure, Program, and Commission All Hardware: PLCs, HMIs, AC
Servos, VFDS, and I/O in one simple environment.
• Control Application Programming: Drag & Drop Ladder, C, or Statement List; de-
velop your PLC, HMI, VFD, and Servo applications in one programming environment.
• Advanced HMI / Web Page Design: Free, full library of Drag & Drop quality im-
ages, plus colorful widgets for Trends, Gauges, and much more.
• Communications:
- Transparent communications between all Unitronics hardware components
- All industrial fieldbus and advanced protocols Simple to configure & imple-
ment
- Build your own protocol Communicate with any third-party device.
• Complex Tasks Made Easy: Auto-tuned PID, data-logging and file management
tools, Recipes, Alarms, multilanguage support, multi-level passwords and more.
• Cloud Connectivity & Notifications: Cloud services, Routers & Modems, MQTT,
SMS, Email and more.
fl Back to TOC
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 50
4. Future-Proofing your Pump Applications: IIoT
You may not need IIoT now, but you will almost certainly need it in the future. Unitronics
customers with remote water installations use UniCloud, Unitronics an end-to-end, scalable
and secure IIoT platform, compatible with Unitronics controllers and MODBUS devices.
These customers design their own dashboards to monitor these installations and to re-
cord data, using UniCloud’s no-code Dashboard Designer to quickly build dashboards
with simple drag & drop elements, easy Widget Wizards for Gauges, Graphs, Charts,
Tables, Maps, and more.
This do-it-yourself approach enables them to take advantage of powerful IIoT technol-
ogy, without any need to invest in programmers, IT or Cloud professionals.
5. Support: Available and Free
Support subscriptions can be costly, and the level of service varies from company to
company.
Unitronics’ customers consistently rate the technical support received from Unitronics
as excellent. Support is personalized and forever and membership in the lively, moder-
ated technical forum are free, providing support 24/7.
In addition, Unitronics maintains a worldwide distribution network, with distributors
that provide local sales and tech support in your local language.
One final point: choosing the same source for all control and automation benefits you
with a single point of contact to smooth your ordering and delivery process.
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 50
4. Future-Proofing your Pump Applications: IIoT
You may not need IIoT now, but you will almost certainly need it in the future. Unitronics
customers with remote water installations use UniCloud, Unitronics an end-to-end, scalable
and secure IIoT platform, compatible with Unitronics controllers and MODBUS devices.
These customers design their own dashboards to monitor these installations and to re-
cord data, using UniCloud’s no-code Dashboard Designer to quickly build dashboards
with simple drag & drop elements, easy Widget Wizards for Gauges, Graphs, Charts,
Tables, Maps, and more.
This do-it-yourself approach enables them to take advantage of powerful IIoT technol-
ogy, without any need to invest in programmers, IT or Cloud professionals.
5. Support: Available and Free
Support subscriptions can be costly, and the level of service varies from company to
company.
Unitronics’ customers consistently rate the technical support received from Unitronics
as excellent. Support is personalized and forever and membership in the lively, moder-
ated technical forum are free, providing support 24/7.
In addition, Unitronics maintains a worldwide distribution network, with distributors
that provide local sales and tech support in your local language.
One final point: choosing the same source for all control and automation benefits you
with a single point of contact to smooth your ordering and delivery process.
fl Back to TOC
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 51
About Smart Sourcing with Unitronics
Founded in 1989, Unitronics develops, produces, and markets a broad range of PLC
controllers, VFDs, Servos, I/O and additional components to suit any size pump ap-
plication.
The synergy of Unitronics’ hardware and software allows you to reduce energy con-
sumption, to use built-in, smart PID control to run pumps close to setpoint, and control
flow and reduce motor energy consumption via VFDs, while rich communication sup-
port enables easy interoperability within a system.
Backed by highly intuitive, free software that enables speed programming, you can hit
the ground running, finishing projects faster with a minimum of hassle. Unitronics con-
troller’s multi-function capabilities simplify system architecture, reducing the need for
multiple components, while embedded, transparent communications via popular Field-
bus and advanced COM protocols enable easy integration and eliminate PLC-to-HMI
wiring. Free personalized, tech support sweetens the deal.
Unitronics is an award-winning leader in advanced control & automation solutions,
providing a single source for pump control and automation application needs. With
three decades of proven reliability in the petrochemicals, energy & environment, water
& wastewater management, HVAC and building management industries, Unitronics is
a smart source for automated precise control of pumps, from hydraulics to simple fill
applications.
Stop the Hidden Leaks: 5 Tips for Smart-Sourcing Pump Automation Controls 51
About Smart Sourcing with Unitronics
Founded in 1989, Unitronics develops, produces, and markets a broad range of PLC
controllers, VFDs, Servos, I/O and additional components to suit any size pump ap-
plication.
The synergy of Unitronics’ hardware and software allows you to reduce energy con-
sumption, to use built-in, smart PID control to run pumps close to setpoint, and control
flow and reduce motor energy consumption via VFDs, while rich communication sup-
port enables easy interoperability within a system.
Backed by highly intuitive, free software that enables speed programming, you can hit
the ground running, finishing projects faster with a minimum of hassle. Unitronics con-
troller’s multi-function capabilities simplify system architecture, reducing the need for
multiple components, while embedded, transparent communications via popular Field-
bus and advanced COM protocols enable easy integration and eliminate PLC-to-HMI
wiring. Free personalized, tech support sweetens the deal.
Unitronics is an award-winning leader in advanced control & automation solutions,
providing a single source for pump control and automation application needs. With
three decades of proven reliability in the petrochemicals, energy & environment, water
& wastewater management, HVAC and building management industries, Unitronics is
a smart source for automated precise control of pumps, from hydraulics to simple fill
applications.
fi Back to TOC 52
Back to the future of the PLC
Programmable logic controllers (PLCs) are not going away any time soon,
and improving technologies combined with user demands will continue their
evolution as a foundational automation platform.
A
lmost 10 years ago, I wrote about the “Future of the PLC” for this publication.
Even back then, it was important to mention that programmable logic controller
(PLC) technology was mature at nearly 50 years old. A decade later, a fair question is
whether today’s PLCs have fully entered senior citizen status, and if future iterations are
destined for the grave.
This discussion is especially relevant considering the rapid—and sometimes seemingly
exponential—acceleration in computing hardware, software, intelligent measurement,
cloud accessibility and communications connectivity. With these and other advances,
information technology (IT) has proliferated steadily into the formerly isolated opera-
tional technology (OT) realm.
While the article discussed the dramatically increasing importance of communications
and connectivity, it did not specifically include the term “industrial Internet of Things”
(IIoT), but today IIoT capabilities are essential for nearly any application.
In light of these developments, here are a few thoughts on what the next decade may
hold for PLC evolution and industrial automation applications.
Remaining true to the task
The core mission of a PLC remains the same as always: To deliver deterministic control
and reliable monitoring of physical field devices, even under challenging operational
Back to the future of the PLC
Programmable logic controllers (PLCs) are not going away any time soon,
and improving technologies combined with user demands will continue their
evolution as a foundational automation platform.
A
lmost 10 years ago, I wrote about the “Future of the PLC” for this publication.
Even back then, it was important to mention that programmable logic controller
(PLC) technology was mature at nearly 50 years old. A decade later, a fair question is
whether today’s PLCs have fully entered senior citizen status, and if future iterations are
destined for the grave.
This discussion is especially relevant considering the rapid—and sometimes seemingly
exponential—acceleration in computing hardware, software, intelligent measurement,
cloud accessibility and communications connectivity. With these and other advances,
information technology (IT) has proliferated steadily into the formerly isolated opera-
tional technology (OT) realm.
While the article discussed the dramatically increasing importance of communications
and connectivity, it did not specifically include the term “industrial Internet of Things”
(IIoT), but today IIoT capabilities are essential for nearly any application.
In light of these developments, here are a few thoughts on what the next decade may
hold for PLC evolution and industrial automation applications.
Remaining true to the task
The core mission of a PLC remains the same as always: To deliver deterministic control
and reliable monitoring of physical field devices, even under challenging operational
fi Back to TOC
Back to the future of the PLC 53
conditions. This has been achieved using specialized
processors, operating systems, and programming
environments, built into hardened platforms. Yet
economies of scale continue to drive the adoption of
mainstream consumer and commercial technologies
into the PLC role, wherever it is practical. The “small-
er, faster, better” maxim has held true and will con-
tinue to do so, but mostly around the faster and better aspects, as the trend to further
miniaturization has leveled off over the past decade.
Figure 1: Now that contemporary open-
source processor platforms are available
in industrial-grade form factors, such as
the AutomationDirect ProductivityOpen,
end users now have options for
integrating traditional automation
methods with more modern IT-based
languages. Courtesy: AutomationDirect
Back to the future of the PLC 53
conditions. This has been achieved using specialized
processors, operating systems, and programming
environments, built into hardened platforms. Yet
economies of scale continue to drive the adoption of
mainstream consumer and commercial technologies
into the PLC role, wherever it is practical. The “small-
er, faster, better” maxim has held true and will con-
tinue to do so, but mostly around the faster and better aspects, as the trend to further
miniaturization has leveled off over the past decade.
Figure 1: Now that contemporary open-
source processor platforms are available
in industrial-grade form factors, such as
the AutomationDirect ProductivityOpen,
end users now have options for
integrating traditional automation
methods with more modern IT-based
languages. Courtesy: AutomationDirect
fi Back to TOC
Back to the future of the PLC 54
Many benefits of electronic component, processor, and solid-state memory advances—
reduced cost, shrinking size, minimized power consumption, and increased capabili-
ty—have already been incorporated into PLCs and other industrial electronics. While
marginal size, cost, and power improvements will continue, the real advances will be
around capabilities.
At this point, platform size is largely constrained by the need for physical wiring to
interface with PLC input/output (I/O) modules. Traditional wired I/O remains necessary,
but in many cases, the connectivity with field devices is shifting to digital networks and
distributed remotely using technologies like IO-Link and wireless.
Multi-core processors incorporated PLC designs now enable deterministic control to be
supplemented with extensive additional computational and communication function. For
over 20 years, the term programmable automation controller (PAC) has been used loose-
ly to describe an industrial controller with greater capabilities than a classic PLC.
While a PAC may have initially seemed like a distinct product compared with a PLC,
time has proven that automation engineers are less concerned with the nomenclature
and much more interested in performance and available features when specifying in-
dustrial automation.
While market offerings range from basic PLCs to complex PACs, the concept of an in-
dustrial control platform has largely merged into a continuous spectrum of capabilities.
Moving forward, users will be willing to consider most any type of underlying hardware
platform or operating system as an automation platform—which may continue to be
called a PLC but will actually be so much more—if it can deliver proven real-time con-
trol, while providing other required advanced computing capabilities.
Back to the future of the PLC 54
Many benefits of electronic component, processor, and solid-state memory advances—
reduced cost, shrinking size, minimized power consumption, and increased capabili-
ty—have already been incorporated into PLCs and other industrial electronics. While
marginal size, cost, and power improvements will continue, the real advances will be
around capabilities.
At this point, platform size is largely constrained by the need for physical wiring to
interface with PLC input/output (I/O) modules. Traditional wired I/O remains necessary,
but in many cases, the connectivity with field devices is shifting to digital networks and
distributed remotely using technologies like IO-Link and wireless.
Multi-core processors incorporated PLC designs now enable deterministic control to be
supplemented with extensive additional computational and communication function. For
over 20 years, the term programmable automation controller (PAC) has been used loose-
ly to describe an industrial controller with greater capabilities than a classic PLC.
While a PAC may have initially seemed like a distinct product compared with a PLC,
time has proven that automation engineers are less concerned with the nomenclature
and much more interested in performance and available features when specifying in-
dustrial automation.
While market offerings range from basic PLCs to complex PACs, the concept of an in-
dustrial control platform has largely merged into a continuous spectrum of capabilities.
Moving forward, users will be willing to consider most any type of underlying hardware
platform or operating system as an automation platform—which may continue to be
called a PLC but will actually be so much more—if it can deliver proven real-time con-
trol, while providing other required advanced computing capabilities.
fl Back to TOC
Back to the future of the PLC 55
Reconciling flexibility with consistency
Although Windows-based systems dominate the consumer and commercial PC world,
and are prominent for the industrial visualization realm, this is not the case for re-
al-time control. PLC/PAC platforms typically run a specialized operating system, al-
though there are some Linux-based options. In very general terms, users must balance
their desire for openness—which provides great flexibility and low product costs—with
the requirement for industrial-grade reliability historically delivered only by proprietary
systems. These proprietary systems also provide a high degree of cybersecurity, albeit
primarily through obscurity and to an extent unfamiliarity to hackers.
For many years there has been a trend, or at least great interest, towards more open
industrial systems, both in terms of hardware platforms and for programming languag-
es. Some end users have applied generic Raspberry Pi and Arduino hardware to imple-
ment automation and data handling projects. Others have avoided experimenting in
this way with consumer-grade products due to concerns about reliability, but now a few
versions of these platforms have been hardened into industrial-grade devices (Figure
1). Users are showing great demand for the ability to combine contemporary program-
ming platforms with proven industrial I/O and hardware.
With such a range of hardware options, the next hurdle for openness has been homog-
enizing the programming environment. Classic PLCs used vendor-specific program-
ming that was difficult to port to other brands. The IEC 61131-3 standard introduced
ordered PLC programing languages and data types, but vendor-specific implementa-
tions still hampered code portability among brands. Eventually, the CODESYS integrat-
ed development environment (IDE) offered a more consistent way to create code using
the standard languages to deploy it cross-platform on industrial controllers.
Back to the future of the PLC 55
Reconciling flexibility with consistency
Although Windows-based systems dominate the consumer and commercial PC world,
and are prominent for the industrial visualization realm, this is not the case for re-
al-time control. PLC/PAC platforms typically run a specialized operating system, al-
though there are some Linux-based options. In very general terms, users must balance
their desire for openness—which provides great flexibility and low product costs—with
the requirement for industrial-grade reliability historically delivered only by proprietary
systems. These proprietary systems also provide a high degree of cybersecurity, albeit
primarily through obscurity and to an extent unfamiliarity to hackers.
For many years there has been a trend, or at least great interest, towards more open
industrial systems, both in terms of hardware platforms and for programming languag-
es. Some end users have applied generic Raspberry Pi and Arduino hardware to imple-
ment automation and data handling projects. Others have avoided experimenting in
this way with consumer-grade products due to concerns about reliability, but now a few
versions of these platforms have been hardened into industrial-grade devices (Figure
1). Users are showing great demand for the ability to combine contemporary program-
ming platforms with proven industrial I/O and hardware.
With such a range of hardware options, the next hurdle for openness has been homog-
enizing the programming environment. Classic PLCs used vendor-specific program-
ming that was difficult to port to other brands. The IEC 61131-3 standard introduced
ordered PLC programing languages and data types, but vendor-specific implementa-
tions still hampered code portability among brands. Eventually, the CODESYS integrat-
ed development environment (IDE) offered a more consistent way to create code using
the standard languages to deploy it cross-platform on industrial controllers.
fi Back to TOC
Back to the future of the PLC 56
However, none of these initiatives addressed the fact that programmers entering the work-
force often preferred to code in more modern IT-based languages such as C++ or Python.
Despite all these efforts heading to openness and modern programming languages,
it seems safe to say that classic ladder logic is here to stay for the foreseeable future.
Ladder logic enjoys a massive installed base, and it remains a simple coding method-
ology preferred by many electricians, technicians, and even developers. Its graphical
style lends itself to basic troubleshooting and typical industrial automation functions,
and its widespread familiarity provides other advantages.
Today most hardware platforms support ladder logic—whether proprietary or imple-
mented via another IDE such as CODESYS—and many also allow other types of cod-
ing methods, which can be mixed-and-matched as needed. Various coding languages
have their own strengths and weaknesses for specific tasks, and most users like to
apply their own judgement when choosing the best tool for solving a problem, while
balancing flexibility against complexity. An added bonus for users is moving outside of
proprietary languages enables them to curate a library of code, which can be deployed
on any type of target hardware, minimizing rework.
The main point today and looking ahead is users desire automation platforms offered
and backed by trusted and experienced industrial suppliers, with provisions for sup-
porting any type of preferred programming language.
Tying it all together with communications
Some of the greatest industrial automation strides over the last decade are associat-
ed with communications improvements, leading to a truly connected factory. As with
Back to the future of the PLC 56
However, none of these initiatives addressed the fact that programmers entering the work-
force often preferred to code in more modern IT-based languages such as C++ or Python.
Despite all these efforts heading to openness and modern programming languages,
it seems safe to say that classic ladder logic is here to stay for the foreseeable future.
Ladder logic enjoys a massive installed base, and it remains a simple coding method-
ology preferred by many electricians, technicians, and even developers. Its graphical
style lends itself to basic troubleshooting and typical industrial automation functions,
and its widespread familiarity provides other advantages.
Today most hardware platforms support ladder logic—whether proprietary or imple-
mented via another IDE such as CODESYS—and many also allow other types of cod-
ing methods, which can be mixed-and-matched as needed. Various coding languages
have their own strengths and weaknesses for specific tasks, and most users like to
apply their own judgement when choosing the best tool for solving a problem, while
balancing flexibility against complexity. An added bonus for users is moving outside of
proprietary languages enables them to curate a library of code, which can be deployed
on any type of target hardware, minimizing rework.
The main point today and looking ahead is users desire automation platforms offered
and backed by trusted and experienced industrial suppliers, with provisions for sup-
porting any type of preferred programming language.
Tying it all together with communications
Some of the greatest industrial automation strides over the last decade are associat-
ed with communications improvements, leading to a truly connected factory. As with
fi Back to TOC
Back to the future of the PLC 57
controller hardware and programming, the story has been one of moving away from
proprietary implementations and towards a more open offering.
Traditional OT-centric fieldbuses, such as DeviceNet, had long offered the reliability
and installation form factors demanded by users. But now wired, and even wireless,
Ethernet variants are dominating, with several leading industrial communications
protocols available. Physical form factor improvements, such as washdown-rated and
connectorized components and power over Ethernet (PoE) now enable Ethernet instal-
lations to be suitable for industrial environments.
Certain OT protocols such as EtherNet/IP, PROFINET, and Modbus-TCP are associated
with makes and models of field devices, while others are optimized for types of auto-
mation tasks (such EtherCAT for motion control). While EtherCAT is not new, the incor-
poration of this protocol natively into more capable PLCs now means low- and medi-
um-complexity motion applications are can be integrated natively into an automation
platform without requiring separate motion controllers.
Ethernet-APL is an OT-optimized media, which makes it easier to deploy wired Ether-
net out to field devices. IO-Link is on the rise as a streamlined fieldbus—even for basic
discrete automation devices—with fit-for-purpose communications capabilities and
intelligence.
Bridging OT to IT to securely enable IIoT applications and data transfer in support of
remote visualization and analytics requires a different class of communication proto-
cols. OPC UA and message queuing telemetry transport (MQTT) are dominant in this
role. While some of their capabilities overlap, there are optimal use cases for both
Back to the future of the PLC 57
controller hardware and programming, the story has been one of moving away from
proprietary implementations and towards a more open offering.
Traditional OT-centric fieldbuses, such as DeviceNet, had long offered the reliability
and installation form factors demanded by users. But now wired, and even wireless,
Ethernet variants are dominating, with several leading industrial communications
protocols available. Physical form factor improvements, such as washdown-rated and
connectorized components and power over Ethernet (PoE) now enable Ethernet instal-
lations to be suitable for industrial environments.
Certain OT protocols such as EtherNet/IP, PROFINET, and Modbus-TCP are associated
with makes and models of field devices, while others are optimized for types of auto-
mation tasks (such EtherCAT for motion control). While EtherCAT is not new, the incor-
poration of this protocol natively into more capable PLCs now means low- and medi-
um-complexity motion applications are can be integrated natively into an automation
platform without requiring separate motion controllers.
Ethernet-APL is an OT-optimized media, which makes it easier to deploy wired Ether-
net out to field devices. IO-Link is on the rise as a streamlined fieldbus—even for basic
discrete automation devices—with fit-for-purpose communications capabilities and
intelligence.
Bridging OT to IT to securely enable IIoT applications and data transfer in support of
remote visualization and analytics requires a different class of communication proto-
cols. OPC UA and message queuing telemetry transport (MQTT) are dominant in this
role. While some of their capabilities overlap, there are optimal use cases for both
fi Back to TOC
Back to the future of the PLC 58
protocols, and users can choose to implement them
simultaneously. Other supporting tools, such as Node-
RED, have become favored as a graphical method for
processing and pushing data to the cloud for consump-
tion by other applications.
From sensor to controller, to on-premises server, to
cloud-based resources, to browser, what does this all
mean? In the “old days,” smaller controllers would have a limited feature set, so larger
devices or multiple integration layers were required to achieve complete connectivity.
Figure 2: Today, even a low-cost
PLC automation platform like the
AutomationDirect CLICK PLUS
is packed with advanced logic
capabilities, essential motion
control, wired/wireless connectivity,
a range of IT/OT communications
protocols, and more. Courtesy:
AutomationDirect
Back to the future of the PLC 58
protocols, and users can choose to implement them
simultaneously. Other supporting tools, such as Node-
RED, have become favored as a graphical method for
processing and pushing data to the cloud for consump-
tion by other applications.
From sensor to controller, to on-premises server, to
cloud-based resources, to browser, what does this all
mean? In the “old days,” smaller controllers would have a limited feature set, so larger
devices or multiple integration layers were required to achieve complete connectivity.
Figure 2: Today, even a low-cost
PLC automation platform like the
AutomationDirect CLICK PLUS
is packed with advanced logic
capabilities, essential motion
control, wired/wireless connectivity,
a range of IT/OT communications
protocols, and more. Courtesy:
AutomationDirect
fi Back to TOC
Back to the future of the PLC 59
Today and into the future, users will want these op-
tions available in even very basic and low-cost auto-
mation platforms (Figure 2).
The role of integrated robotics
For many years, robotics has largely existed as a spe-
cialty subset of automation, requiring custom integra-
tion into upstream and downstream systems. This is morphing as robotics in general,
Figure 3: Robotics represents a fast-
growing area of industrial design, and
the demand for capable automation
platforms and associated sensing
technologies will increase as users
seek to thoroughly integrate robotics
into their operations. Courtesy:
AutomationDirect
Back to the future of the PLC 59
Today and into the future, users will want these op-
tions available in even very basic and low-cost auto-
mation platforms (Figure 2).
The role of integrated robotics
For many years, robotics has largely existed as a spe-
cialty subset of automation, requiring custom integra-
tion into upstream and downstream systems. This is morphing as robotics in general,
Figure 3: Robotics represents a fast-
growing area of industrial design, and
the demand for capable automation
platforms and associated sensing
technologies will increase as users
seek to thoroughly integrate robotics
into their operations. Courtesy:
AutomationDirect
fi Back to TOC
Back to the future of the PLC 60
and collaborative robotics (cobots) in particular, look to be among the single largest
growth areas throughout all industrial automation over the next 5 to 10 years (Figure
3). In a related development, vision systems have advanced tremendously in the past
decade, and many are very compatible with robots, allowing easy integration in a host
of applications.
Modern automation platforms need to be prepared to keep up with this changing
landscape by providing the requisite processing power, programming instructions, and
connectivity to seamlessly integrate with robotics and vision. A contemporary PLC with
these capabilities located near field-installed robotics offers a distinct advantage as an
automation platform.
AI’s role in the PLC’s future
No future-looking industrial automation article written in 2024 could overlook the poten-
tial impacts of artificial intelligence (AI) and machine learning (ML). However, much of the
current buzz is around using AI/ML in a live “runtime” role to analyze and react to con-
ditions. As an automation platform, PLCs are not currently ideally suited for this task, but
some advanced versions may be able to run live AI/ML algorithms in the future.
Instead, PLCs are well placed to act as the field interface for higher-level AI/ML re-
sources, providing users with abundant, responsive and contextualized data. They also
can implement actions dictated by algorithms.
On the other hand, generative AI (Gen-AI) is poised to play a bigger role with PLCs in
coming years from a code creation standpoint. Development environments with care-
fully integrated AI support tools could help users—perhaps even relative newcomers
Back to the future of the PLC 60
and collaborative robotics (cobots) in particular, look to be among the single largest
growth areas throughout all industrial automation over the next 5 to 10 years (Figure
3). In a related development, vision systems have advanced tremendously in the past
decade, and many are very compatible with robots, allowing easy integration in a host
of applications.
Modern automation platforms need to be prepared to keep up with this changing
landscape by providing the requisite processing power, programming instructions, and
connectivity to seamlessly integrate with robotics and vision. A contemporary PLC with
these capabilities located near field-installed robotics offers a distinct advantage as an
automation platform.
AI’s role in the PLC’s future
No future-looking industrial automation article written in 2024 could overlook the poten-
tial impacts of artificial intelligence (AI) and machine learning (ML). However, much of the
current buzz is around using AI/ML in a live “runtime” role to analyze and react to con-
ditions. As an automation platform, PLCs are not currently ideally suited for this task, but
some advanced versions may be able to run live AI/ML algorithms in the future.
Instead, PLCs are well placed to act as the field interface for higher-level AI/ML re-
sources, providing users with abundant, responsive and contextualized data. They also
can implement actions dictated by algorithms.
On the other hand, generative AI (Gen-AI) is poised to play a bigger role with PLCs in
coming years from a code creation standpoint. Development environments with care-
fully integrated AI support tools could help users—perhaps even relative newcomers
fi Back to TOC
Back to the future of the PLC 61
to the field—develop useful automation logic based on libraries and proven code. AI,
used as a development tool, could help speed development times, improve code reli-
ability and minimize redundant or repetitive labor.
The future PLC is one piece of an automation platform
Over the next decade, PLCs as we know them will certainly not go away, even if they
are referred to as PACs, or edge controllers, or automation platforms, or something
else. There will be no single controller technology that can fulfill all roles at all price
points.
Instead, PLCs will continue to evolve based on available technologies and user de-
mand, just as they have done so for the past five decades. The priority will be deliver-
ing real-time control and reliable monitoring, but they will add even better program-
ming and connectivity functions to improve the user experience, and the speed at
which projects can be delivered.
Jeff Payne
Jeff Payne is the director of business development at AutomationDirect.
Back to the future of the PLC 61
to the field—develop useful automation logic based on libraries and proven code. AI,
used as a development tool, could help speed development times, improve code reli-
ability and minimize redundant or repetitive labor.
The future PLC is one piece of an automation platform
Over the next decade, PLCs as we know them will certainly not go away, even if they
are referred to as PACs, or edge controllers, or automation platforms, or something
else. There will be no single controller technology that can fulfill all roles at all price
points.
Instead, PLCs will continue to evolve based on available technologies and user de-
mand, just as they have done so for the past five decades. The priority will be deliver-
ing real-time control and reliable monitoring, but they will add even better program-
ming and connectivity functions to improve the user experience, and the speed at
which projects can be delivered.
Jeff Payne
Jeff Payne is the director of business development at AutomationDirect.
Content Archive
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[email protected]
We would love to hear from you!PLCs
2024 Spring Edition
2024 Winter Edition
2023 Fall Edition
2023 Summer Edition Thank you for visiting the PLCs eBook!
If you have any questions or feedback about the contents
in this eBook, please contact CFE Media at
[email protected]
We would love to hear from you!PLCs
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