Margin variances of custom vs standard control panels

Custom vs. Standard Control Panels: Why Custom Builds Make 2x the Profit (Part 1)

Control panel, Systems, ,

Recently, I looked into the gross margin spread between custom and standard industrial control panels. How feasible is it to increase the availability of customized control panels—and can it be done profitably?

The industry numbers reveal an interesting paradox:

  • High-volume OEM builds: typically operate at 15%–25% gross margins.

  • Custom Engineer-to-Order (ETO) panels: routinely command 35%–50% gross margins.

 

Margin variances of custom vs standard control panels
Custom vs Standard ( Note: Engineering dollars per panel)

At first glance, this feels counterintuitive. If a custom build requires double or triple the engineering time amortized across a lower volume of panels, shouldn’t those extra labor hours erode profitability?

The short answer: No. Custom engineering is often billed directly to the project rather than absorbed as overhead. While custom systems carry higher risk due to technical ambiguity and site-specific variables, experienced panel builders mitigate this risk through modular sub-assemblies and deep niche specialization.

Here is why the math works out the way it does:

  1. Cost-Plus vs. Value-Based Pricing: Standard volume panels face intense competitive bidding, forcing shops into cost-plus pricing. Custom ETO builds solve complex, site-specific challenges (like strict UL 508A specs, high short-circuit ratings, or tight legacy footprint retrofits). The client isn’t paying for raw sheet metal and terminal blocks—they are paying to eliminate risk and avoid costly plant downtime.

  2. Engineering as Revenue, Not Overhead: In high-volume manufacturing, non-recurring engineering (NRE) is fixed overhead amortized over hundreds of units. In custom projects, specialized engineering labor, CAD drafting, and Factory Acceptance Testing (FAT) are billable line items—often billed at a 2.5x to 3.5x multiplier on engineering wages.

  3. The Risk Premium: Custom projects inherently carry technical ambiguity, so builders factor contingency buffers into quotes. When a shop executes cleanly without scope creep, that risk buffer flows straight to the bottom line as pure profit. (The catch: execution must remain disciplined so contingency hours aren’t burned during testing or rework).

Bottom Line: While high-volume standard builds provide baseline shop throughput and predictable baseline cash flow, custom systems act as the true gross-margin engine.

The Custom vs. Standard Series

This is Part 1 of a 5-part series exploring control panel economics and engineering strategy:

  • Part 1: Profit Margins Explained (You are here)

  • Part 2: What Actually Makes a Panel “Custom”?

  • Part 3: The Dollar Split: Where Does the Budget Actually Go?

  • Part 4: What’s in the Cost: Hidden Drivers of Panel Fabrication

  • Part 5: How to Defend Your Bottom Line on ETO Projects

Always interested in hearing from folks on the shop floor or in the control panel space: Does this margin spread reflect what you see in your own operation? Drop your thoughts in the comments below.

 

 

 

 

 

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It’s Getting Hot in Here: Thermal Management for Control Panels

Control panel, ,

Building on last weeks Control Panel Insights, this weeks list is thermal management tips from industry. Control panels get hot, things start to fail. Equipment failure from poor climate control, heat stagnation, or layout problems ties into the  42% of unplanned equipment downtime experienced in industry. Following a few rules alleviates most of the problems.

1. The 10°C Life Expectancy Rule

Heat is the primary factor in premature component aging. For every 10°C increase in operating temperature, the life of electrolytic capacitors are cut in half. Beyond capacitors, thermal stress destabilizes solid-state semiconductors. Heat introduces electron gate leakage and accelerates microfluidic trace degradation – resulting in exeuction latency, logic corruption and sudden system reboots.  Experienced your computer rebooting suddenly, check the fans and ventilation. 

Deep Dive/ Source: Read the physics behind electrolyte degradation in the Cornell Dubilier Capacitor Lifetime Technical Paper or review standard semiconductor acceleration modeling via the Texas Instruments Component Lifetime Report.

2. Managing Stratification ( Heat Layers)

Air naturally layers in an enclosure. The top of your cabinet acts as a “hot zone” where internal air flows accumulate. Because of this vertical gradient, we must plan layout locations based on component thresholds. While heavy power distribution can survive higher limits, sensitive components like PLCs and power supplies have a much lower critical ceiling (often 40degC) and must be kept out of that upper ceiling.

3. VFD Vertical Clearance

VFDs are essentially furnaces for the rest of your components. A “clear sky” zone—usually 4 to 6 inches—above the drive allows for the exhaust plume to dissipate without affecting sensitive components above or around it.

Deep Dive: The Schneider Electric Altivar Installation Manual covers standard clearance rules. For a brand-agnostic engineering framework, consult global enclosure spacing standards like IEC 61439-1 (Low-voltage switchgear and controlgear assemblies). The standard uses a mathematical verification of temperature rise and clearance paths instead of a steadfast range like 4-6 inches.

4. The Nuance of “Zero-Stack” Spacing

Modern drives often claim they can be mounted side-by-side with no gap. Just remember the fine print: that often comes with specific derating or ambient temperature caps to manage lateral heat transfer.

Verification: Schneider Electric Altivar Technical Documentation.

5. Avoiding Airflow “Dead Zones”

Panels with high-CFM fans that still fail because the wire duct is too dense. We look for at least 30% unobstructed cross-sectional area to ensure air actually moves through the components rather than around them.

Insight: Established Industry Best Practice.

To Conclude : Strategic Place Components 

The layout of components for best results is to  keep high-sensitivity digital logic (like PLCs, communication modules, and I/O) in the cooler bottom-left regions. Big heat producers like VFDs, servo drives, and transformers belong in the upper-middle zones. This geometry effectively accounts for the natural rise of air density currents to move thermal energy away from logic and more sensitive electronics.

 

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Top 5 Control Panel Insights – From Industrial People

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This week, I reviewed the most engaging industrial control panel threads on r/plc and used a Gemini prompt to aggregate the community’s best advice:

  • Thermal Management: To prevent premature failure from rising heat, avoid placing heat-sensitive devices above heat-generating ones like Variable Frequency Drives (VFDs). This seems obvious, but nuances exist—I will expand on this in a deeper dive later.

  • The “25% Expansion Rule”: Always leave 25–30% open space on back panels and DIN rails. This allows for future system modifications without requiring a full cabinet replacement.

  • Back Panel Labeling: Mount component labels directly to the mounting plate rather than wire duct covers. This ensures technicians can still see the labels during maintenance, and prevents them from getting lost when someone removes the duct covers.

  • EMI Mitigation: Maintain strict physical separation between high-voltage AC power and low-voltage DC control signals to prevent electromagnetic interference. You cannot ignore this rule. It is like smoking cigarettes: EMI will be the diagnosis for all future mysterious ailments of the system.

  • Hinge Wire Management: Use “S” or “U” shaped service loops at door hinges so wires twist rather than pull, which prevents mechanical fatigue.

Next week, I will update these bullets with links to deep-dive posts—especially for points 1 and 4.

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Reddit Highlights (March/ April 2026 ): The UL 891 Switchboard Landscape

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Summary: Lead times for Tier 1 equipment have hit a critical average in 2026, forcing engineers to navigate the complex selective coordination requirements of UL 891 through creative interlocking and regional shop pivots.

Series Overview

Once a month, I am pulling a Gemini summary of technical trends being discussed on reddit. This first one is focused on UL891 Switchboards.

1. The 12-Month “Lead Time” Floor

Supply chain discussions in April 2026 show a “new normal” where lead times for major manufacturers are hovering between 12 to 14 months for standard switchgear and transformers.

  • The Trend: To keep projects on schedule, there is a massive surge toward regional UL-certified custom shops.

  • The Advantage: These shops can often assemble a UL 891-compliant board in 8–12 weeks by using off-the-shelf components, bypassing factory backlogs.

  • The Field Insight: Commercial electricians report projects sitting idle for over a year waiting on substation-level gear, leading to a hunt for refurbished breakers in secondary markets.

Source Thread: Twelve month transformer lead time on our current project (r/electrical – March 26, 2026)

2. Selective Coordination 

A recurring pain point is the struggle to meet NEC selective coordination requirements (Articles 700/701) using UL 891 gear compared to UL 1558 alternatives.

  • The Conflict: UL 891 switchboards are typically tested for a 3-cycle withstand. To protect the bus within this window, main breakers often require low “Instantaneous” settings.

  • The Risk: This causes the main breaker to “race” downstream branch breakers. If a minor fault occurs, the entire main trips, resulting in a total facility blackout.

  • Field-Tested Solutions: * Zone Selective Interlocking (ZSI): Utilizing restraint signals so the main breaker “waits” while the branch clears.

    • Electronic Trip Units (ETU): Advanced units allowing for Short-Time region adjustments to carve out coordination paths.

Source Thread: Low Voltage Switchgear (UL 891) Selective Coordination and Field Testing (r/PowerSystemsEE – April 2026)

3. Data Centers “Hoarding” the 2026 Market

A massive percentage of industrial electrical equipment produced in 2026 is being funneled directly into AI and hyperscale data centers.

  • The Scarcity: Hyperscalers have pre-purchased entire manufacturing runs of switchboards and MV transformers, pushing small-to-medium facilities to “low priority” status.

  • Field Consensus: The industry is hitting an inflection point where the “interconnection queue” and equipment backlogs are making 2026 a year of strategic waiting.

Source Thread: US Data Centers facing delays due to electrical component sourcing (r/GenAI4all – April 6, 2026)

Disclaimer: This content is for informational purposes only and represents community trends as of April 2026. It does not constitute professional engineering advice. All electrical work should be performed by qualified personnel in accordance with NFPA 70E, local codes, and manufacturer specifications.

This is Part 1 of an ongoing monthly series. Stay tuned for future deep dives.

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Control Panel Layout: Top Tips with some Photos

Control panel, Systems, , ,

Amongst the control panel layout tips out there, some are practical, many are good and some are downright weird. There are is a wealth of it in the /PLC sub-reddit. Some of it is amusingly opiniated:

 

The following is my collection of top tips on control panel layouts. A few of the panel posts from Reddit are embedded below. Will add more pointers as I come across them.

 

Busbar candy
byu/Otherwise_Feed_3320 inPLC

1. Heat rises

Do the heat calculations. Enclosure vendors usually have free tools for this like this .

    • If ventilation is needed, fan at the bottom, exhaust at the top, not the other way around. Hot air rises and leaves the panel, cool air comes in the bottom.

2. Power protection components at the top. Circuit breakers, disconnects. The temperature rating on circuit breakers are usually higher than the average PLC, drive or anything that has electronics for that matter. Example here – 30A breaker from SE has an operational ambient of 158 degF/70 degC. Accessibility and safety is also better with power devices at the top. 

3. Incoming power. This really depends on the install site/location. If you have a choice, some would argue that’s it’s better for incoming power to come in from the bottom. With gravity, holes and inlets at the top of the panel have poor contingencies in the event of condensation or dirt coming in( or even water ingress- say NEMA 4/4X failure situations) . 

4. Wire labels, terminals, and wire markers

    • Avoid putting the label on the device. If the device gets replaced, the label goes with it.
    • Sometimes end users may require label on device also. Check before it gets to the FAT
    • Harmonize labelling such that it can be traced back to schematics. This will help with maintenance folks and any troubleshooting efforts.

5. Wireway

    • Vertical runs should intersect with a horizontal run such that the horizontal run stops the vertical cover from sliding down
    • Plan it out such that control wiring is separated from power wiring. If they intersect, make it perpendicular.
    • Read on to number 6.

6. Electromagnetic interference

      • Separate 480Vac and  24Vdc ( control and communications) wires. 
      • If they have to cross, it’s best done perpendicularly- ie. they cross at a 90 deg angle. Still avoid having them in proximity. Good explanation of this here
      • Additional sleeving or barriers for EMI mitigation if needed.

 

7. Spacing If the project allows for it, allow for some room between devices, PLC’s, drives, power supplies. This helps with maintenance accessibility. Also, it makes way for future expansions. More I/O if the PLC needs it, another drive …etc..

My new office 😉
byu/adi_dev inPLC

8. Ground connections

    • Spec grounding washers installed and properly torqued to bite through the paint

9. Network cabling

  • Use pre-terminated cables where possible. From a good vendor, reliability is better. 
  • From item 6 above, separate controls communications cables from the power wiring.

10. Maintenance and usability

  • Add a rack on door for reference material

 

“I´m tired boss…”
byu/andisosh inPLC

Will come back and add more as I find it…

 

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VFD’s and Long Motor Leads

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Recently I came across an application where multiple motors were failing at a single site. This facility utilized VFDs to control several rooftop AC induction motors. The repeated motor failures raised concerns about the possible causes, prompting a deeper investigation into the relationship between long motor leads, motor failures, and VFDs.

Long Motor Leads + VFD’s

The use of long motor leads can cause issues in VFD-driven motors. Voltage reflections and voltage magnification can occur, leading to voltage spikes that can exceed the motor winding insulation capabilities. These spikes, if left unaddressed, may result in premature motor failure due to insulation degradation.

VFD Strategies for Long Motor Leads

 

  1. Adjusting Carrier Frequency: Reducing the carrier frequency of the VFD can help minimize the impact of voltage reflections and the risk of motor failure due to long motor leads. However, this may result in increased audible noise and reduced motor efficiency, so finding an optimal balance is crucial.
  2. Motor Chokes: Installing motor chokes, also known as output reactors can help mitigate voltage reflection and reduce the risk of insulation breakdown.
  3. Motor Insulation Ratings: Using motors with higher insulation ratings, such as those designed specifically for use with VFDs, can help protect against voltage spikes and reduce the risk of motor failure.
  4. Proper Grounding: Ensuring proper grounding practices can help minimize bearing currents and their associated motor failures. While this is not directly related to motor lead length, longer lead lengths can contribute to conditions that cause bearing currents. Some examples of ‘fluting’ and bearing issues here: https://empoweringpumps.com/est-aegis-protect-motors-from-variable-frequency-drive-induced-bearing-damage/
  5. Cable Shielding: Using shielded motor cables can help reduce electromagnetic interference and protect the motor from high-frequency voltage pulses.

For reference, the formula for the reflection coefficient is below. The greater the mismatch, the greater the voltage amplification factor.

                                   R = (Z_load – Z_source) / (Z_load + Z_source)

                                   where:

                                  R represents the reflection coefficient

                                  Z_load is the impedance of the load (in this case, the motor)

                                  Z_source is the impedance of the source (in this case, the VFD)

The formula for the voltage amplification factor:

                                V_max = 1 + |R|

      where:

                            V_max represents the maximum voltage on the line

                           |R| is the absolute value of the reflection coefficient

Another important note is in situations where there are multiple motors driven by a single VFD, the length of cable to each VFD is summed up as the total motor cable length calculation.

Motor Issues Not Caused by the VFD

There are other motor failure scenarios that get misattributed to VFD’s. These may continue occurring even with mitigation techniques above. As such, it’s important to rule these out beforehand. Some common examples:

  1. Environmental Factors: Exposure to harsh environmental conditions, such as extreme temperatures, humidity, or contaminants, can cause motor failures. These issues may be mistakenly linked to VFDs when they are actually the result of inadequate motor protection or improper maintenance practices.
  2. Mechanical Failures: Mechanical issues, such as misalignment, imbalance, or excessive vibration, can lead to motor failures. These problems may be incorrectly attributed to VFDs when they are actually caused by issues within the mechanical system, such as worn-out bearings, loose components, or improper installation.
  3. Overloading: Overloading a motor, either by exceeding its rated capacity or by running it for extended periods at high loads, can result in overheating and failure. This type of failure might be incorrectly attributed to VFDs when it is actually due to improper motor sizing or incorrect application.
  4. Electrical Issues: Motor failures caused by electrical issues, such as short circuits, phase imbalances, or power quality problems, can also be mistaken for VFD-related failures. These issues may stem from faulty wiring, improper grounding, or voltage fluctuations in the electrical supply.
  5. Inadequate Lubrication: Insufficient or improper lubrication can lead to bearing wear and premature motor failure. This type of failure may be misattributed to VFD-related bearing currents when it is actually caused by poor maintenance practices or the use of inappropriate lubricants.
  6. Design or Manufacturing Defects: Motors with inherent design or manufacturing defects may experience premature failure. These failures can be incorrectly linked to VFDs when they are actually the result of flaws in the motor’s construction or assembly.

 

Conclusion:

While long motor leads can pose challenges for VFD-driven systems, by understanding the risks, adjusting VFD setup and settings, and taking appropriate preventative measures, it is possible to mitigate the risk of motor failures. Additionally, recognizing motor failures that are commonly misattributed to VFDs can help ensure accurate diagnosis and effective solutions. By incorporating proper grounding, choosing the right motor insulation ratings, and utilizing motor chokes and cable shielding, you can enhance the performance of your VFD-controlled moto

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Unlocking the Power of AI at the Edge: Essential Data Points for PLC-based Applications

PLC,

The buzz around Artificial Intelligence (AI) has been hard to ignore, and it’s not just the trade publications fueling the hype. As someone who has been cautiously optimistic about AI, I can’t help but feel myself leaning more towards a pro-AI stance as I witness its transformative impact. With the advent of cutting-edge AI-based tools like ChatGPT, it’s clear that AI is no longer just a futuristic concept, but a powerful tool that’s already changing the game.

While AI has been steadily making its way into automation applications, particularly in vision systems, there are countless other use cases for machine learning and AI at the edge. For years, the limitations of memory, processing power, physical form, and price have hindered progress at the edge. However, with advancements in PLC products, these barriers are rapidly being overcome. The question now is, what data do you need to effectively implement an AI application at the edge?

To answer this question, the table below was compiled based on AI applications in industrial automation application.

AI Application Data Points Needed for Implementation
Predictive maintenance Real-time sensor data, historical maintenance records, equipment operating conditions, and environmental conditions.
Fault detection and diagnosis Sensor data, historical data on faults, and their root causes, machine operating parameters, environmental conditions.
Quality control Real-time sensor data, historical quality control data, product specifications, process parameters.
Energy optimization Real-time sensor data on energy consumption, machine operating conditions, historical energy consumption data, environmental conditions.
Production planning and scheduling Production data, inventory data, supplier data, machine data, order data, production schedules, and delivery schedules.
Asset tracking Real-time sensor data on asset location, usage, and maintenance records.
Supply chain management Historical sales data, real-time demand data, inventory data, supplier data, shipping data, transportation data.
Process optimization Real-time sensor data on machine operating conditions, production data, quality data, historical process data, environmental conditions.
Root cause analysis Historical production data, fault data, maintenance records, quality control data, environmental data.
Machine learning-based control Real-time sensor data on machine operating conditions, historical machine data, environmental conditions, and production data.
Automated decision-making Real-time sensor data, historical data on machine performance, historical maintenance records, production schedules, and delivery schedules.
Real-time monitoring Real-time sensor data on machine operating conditions, production data, quality data, and environmental conditions.
Autonomous robots Real-time sensor data, machine operating data, production data, environmental data.

 While this list is a higher level view of relevant data for different applications, there are other data factors. These include data quality, quantity, and accessibility, as well as considerations around data privacy and security. In some cases, a data storage device may be needed from which data is pulled back into the PLC as needed. Also ,the elephant in the room is what type of algorithms and AI functions can a PLC actually execute. More to delve into on all these points. One thing is for sure, the final solution is going to be much more involved than a two letter acronym (AI) infers.

Moving forward, my aim is to be concise and informative in posts. If you’re interested in learning more about the trends, challenges, and opportunities in AI implementation at the edge, be sure to subscribe. In future posts, we’ll explore other aspects of AI at the PLC, and I welcome your comments and requests for specific topics. 

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Back on the blog, ChatGPT and Real-time Industrial Comms. Protocols

PLC, Systems, , ,

After a 5 year break from Drives & Systems, I’ve returned! 

I’ve stayed active in the industrial automation space and worked through a range of machine automation projects at Schneider Electric over the last few years. From robotics and motion through HVAC and pump control systems. Lots learnt and and a lot to capture.  Hopefully capturing some of it here comes as a benefit to others.

Wasn’t sure what I was going to find here but I have come back to some interesting stats on the site. Also some good insight around PLC programming topics users engaged with most here. For instance users seem to have landed here while googling for info on Codesys arrays. This is a promising development in the industrial controls world, knowing that data structures are being used more at the PLC level. Will expand on some of this insight and the topic of arrays in PLC programming in a future post.  

For today, I’ve been exploring the usage of ChatGPT in industrial automation. The combination of large language model processing and reinforcement learning along with what seems to be a substantial data set has led to a pretty amazing outcome. More importantly, it will have some strong use cases in industrial automation too. The use cases from code generation to building specifications, data collection to troubleshooting will likely unfold more and more in the coming months and years. 

A query I took to ChatGPT recently was to compare a few different real time Ethernet communication protocols. While some of this may be outdated since the data references are from September 2021, the output generated was quick and definitely a great reference for automation industry folks.

Whether working through a specification or just looking to learn about the different protocols, this will come in handy. 

One important point, the quality of the query makes all the difference. For example when I queried a comparison with Sercos, the outcome was totally different from Sercos III which is newer. So be precise on the query. 

Network

EtherCAT

SERCOS III

Ethernet/IP with CIP motion

Architecture

Centralized controller to multiple devices

Centralized controller to multiple devices

Distributed control system (devices communicate directly)

Topology

Line, Tree, Star

Line or ring network

Star, Linear, Ring

Data Transmission

Asynchronous

Asynchronous

Synchronous

Data Transfer Rate

Up to 10 Gbps

Up to 100 Mbps

Up to 100 Mbps

Cycle Time

100 ns

31.25 μs

Up to 16 μs

Determinism

 Highly deterministic Highly deterministic Moderately deterministic

Jitter

Very low

Low

High

Synchronization

Hardware-based

Hardware-based

Software-based

Scalability

Good

Limited

Good

Real-time Communication

Yes

Yes

Yes

Security

Good

Good

Good

Descriptions of each area of comparison:

Row Description
Architecture The relationship between the central controller and the network devices, including whether the network is centralized or distributed, and whether devices communicate directly with each other or through the central controller.
Topology The physical layout of the network, including whether it is a line, ring, or star network, and how devices are connected to the network.
Data Transmission The method used to transmit data on the network, including whether it is synchronous or asynchronous.
Data Transfer Rate The maximum rate at which data can be transferred on the network, typically measured in bits per second (bps) or megabits per second (Mbps).
Cycle Time The time it takes for one complete cycle of communication on the network, including the time it takes for the central controller to send a command to a device and receive a response.
Determinism The degree of consistency in the time it takes for communication to occur on the network, with high determinism indicating a consistent and predictable communication pattern.
Jitter The amount of variation in the time it takes for communication to occur on the network, with low jitter indicating a consistent and predictable communication pattern.
Synchronization The method used to synchronize communication between devices on the network, including whether it is hardware-based or software-based.
Scalability The ability of the network to accommodate a varying number of devices without significantly impacting its performance or requiring major changes to the network architecture.
Real-time Communication The ability of the network to support real-time communication, which is critical for industrial automation applications where precise timing is necessary.
Security The level of security provided by the network, including measures to prevent unauthorized access, data loss, or data corruption.

References:

 

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Troubleshooting industrial control systems – Tips and pointers

HMI, PAC, PLC, Systems, VFD

Everything is hooked up but something isn’t working. It worked before but not right now. Or, it’s a new system and you haven’t got it working yet. In any case, troubleshooting industrial controls systems usually involves a repeatable approach or pattern of actions.
 

1. Break the system down into components.

There is a root cause to what is going wrong. Each system is made of of multiple components – software and hardware. To zero in on the root cause, check if  each part/component/sub-part of the system works. Example: PLC not communicating with VFD over Modbus. Questions to ask and things to check:
  • Check if the VFD responds to Modbus polls from a Modbus simulator on your computer.
  • Alternately, if there is another PLC, preferably identical, hook it up to the drive and download the same program. Check if it communicates.
  • If there is another VFD available, preferably one that is known to be functional. Also preferable if its of the same type, hook that up to the PLC. Check if it communicates.

Note: Check that the communication settings in the PLC and VFD are correct.

 The concept here is to test individual components to zero in on the root cause.
 
 

2. Go deep into the workings of each sub-component- including inputs, outputs and the software when possible.

This becomes easier if you know which subsection of each component may be suspect. To the communications breakdown example above, it could be the serial port ( hardware) or the serial communication settings( software). This provides for immediate leads to follow. 

In any case, when troubleshooting industrial controls address the obvious first, and then go deeper into each sub-component. Confirm that everything is plugged in and powered up correctly. Can’t count the number of times something wasn’t working … because it wasn’t powered up.

3. Bring in alternative/replacement components, if available.

This includes replacement cables. Depends on the stage / I.e development, legacy/installed. This is noted described in item 1 above. The implication here is to consider carrying spare parts to a site when possible. If this is not possible, consider alternatives like software to test for specific functionality.
 

4. Don’t alter too many characteristics at a time.

Issues are sometimes a combination of two things happening. Example: PLC won’t communicate with an HMI. The HMI was replaced and the problem persists. The old HMI was connected back in and the PLC replaced,- the problem remained. Replaced the PLC and HMI and figured out that some kind of wiring issue had taken out the serial ports on both devices.  Moral of the story: Check one component and then consider combinations.
 
 

5. Use software where possible.

One example noted in item 1 above. Another example for ethernet communications troubleshooting is a tool like Wireshark.
Use case:  Watch communication lines for packets coming through and sequence of events.
 

6. Document testing and troubleshooting efforts.

Write down the sequence of tested items. Makes a big difference after you go through several hours of troubleshooting and forget what has been tested. Also, take pictures as much as possible. Helps when recapping items covered or when researching sub components in front of your computer.
 

7. Consider the environment, timing and non- obvious of issues.

Time and space are at the core of things. Noise from close by systems, or an environmental effect at the same time of day may cause intermittent issues. This goes back to non-obvious factors to consider.
There may be non-obvious factors that may affect things. One example is a electrical noise issues. Co-located power wiring or bad grounding practices could affect this.
Another example of a non-obvious factor may be related to people or process factors. Example: an operator may be shutting down a device or parts of a system and not powering them up again correctly.  
Another example: someone updated the firmware to one of the devices and it doesn’t communicate to the other devices any more. The problem here may be more of a  process issue but knowing if the firmware was recently updated provides leads for next steps.

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PLCTalk Pick of the Week: PLC programmer Laptop Specs- 2016 edition

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PLC programming, CAD drawings, SCADA packages and virtual machines. These are some of the resident software suites on the average automation or control professionals computer today. This post is mainly about the hardware needs to get the job done.

 

Picking a laptop for automation and control engineers

Based on recent discussions on PLCTalk, the specifications vary based on preference. Some of the common requirements mentioned:

Screen Size:

A 15″ screen laptop is the sweet spot for ease of travel and ease of troubleshooting while onsite. Anything less makes the onsite work, specifically if programming is involved, a little harder. Anything more makes for a bulky laptop to travel with.

Last year, I had two programmers show up in PLC programming classes with Surface Book style tablets. With the i7 processors, the Surface performed well. With the screen size, they struggled in maneuvering through the programming environment. Followed up with one of them this year and they had moved back to a larger screen laptop. PLC Programming with the magnifying tool in Windows is not practical.

 

Processor

The recommendation is a i7 type processor with 3GHz clock. My current machine has a 2.8GHz spec and has been great. Performance with 2 VM’s , HMI software and PLC software running simultaneously noted on screen cap below.

For the MacBook folks, this article talks a bit more about picking processors.

 

RAM

The RAM requirements vary. With virtual machines being a common place to house several different control software suites- PLC and SCADA environments, RAM requirements are a minimum of 16GB .

 

PLC Programmer Laptop RAM considerations
Firing up a single VM with some PLC and HMI software running on the host machine. There could be a need to refer to a program in a VM while writing another program.

Based on a the Windows performance monitor, having one HMI software, one PLC programming environment and one VM took the memory usage up to about 14GB. Note, this number is based on the allocation on your VM’s. Also, it may vary based on the various software suites.

PLC Programmer Laptop RAM considerations
Firing up a second VM with some PLC and HMI software already running brought my system up to 18GB. This measurement is right after starting it up. It will probably go up further over the next few hours.

A PLC programmer laptop option needs to have lots of RAM. I would recommend 32GB.

Hard drive

The SSD seems to be the way to go.  They are generally more shock resistant. Working with PLC’s  often means being onsite at various locations. This may even apply to plant based folks who may have to carry  Also they are quieter.

Requirement would be at least 500GB.

Operating System

Most industrial automation software suites have traditionally been Windows based. Having said that, much feedback I have received regarding MacBook (Pro’s) have been quite positive in terms of performance. That sentiment it shared on this thread.

Mac users may use Boot Camp to get Windows running. Alternatively, many do report using VM’s.

I use Windows 7 Professional. Windows 8 compatibility is common among software suites out there currently.  Some even support Windows 10. Having said that, industrial automation is usually slow to adapt to new OS versions.  Some have reported good results and some report problems. This uncertainty keeps me at Windows 7.

Battery Size:

Hooking up to a power source onsite can sometimes be cumbersome. The tradeoff on some of the more powerful machines has been that the battery drains quickly.  Consensus is that the MacBook Pro runs all day on a single charge. This goes back to the OS discussion above.

My quad core Lenovo W541 holds a charge for about 1.5 hours. I don’t hold the battery requirement to high on my priority list. If you do, check it out while shopping. Be cautious, as the advertised values might not hold true. They are dependent on your performance and usage.

One absolute comparison, is to check the ampere-hours (Ah) ratings among your options.

 

Connection Ports:

Forget the serial port. Get an adapter.

Get a machine with at least 3 USB ports.

Some other considerations:

Numeric keypad might help for some work functions. If the laptop doesn’t come with one, there are USB connectable options online.

DVD players can be left out as Installers are increasing available in downloadable software packages. If required, a portable DVD player can be used.

Back-lit keyboards may be useful for work in environments that are not well lit. Not a requirement I considered but noted in the thread.

The actual picks:

Lenovo P50

Dell Precision

MacBook Pro

Dell E6440

I’ve used Dell’s, HP’s andLenovo’s in recent years. My pick for stability and performance right now is the Lenovo. It may be biased to the hardware specs on this current unit. The previous units also had good specs for their time.

In all, the package is probably going to be about USD$2000 or higher. Shopped during the Black Friday sale last year and Lenovo had a great deal on the W series. Probably due to that series being phased out. The price was down to $1700-ish for a  32GB RAM, i7, 500GB SSD setup.

The threads discussing the topic on PLCTalk are here and here.

 

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