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Migration is Key to Support & Transform Legacy Industrial
Infrastructure (Local & Distributed) to IP-Based Networks
PCN Technology, Inc. (PCN)
16450 Via Esprillo
San Diego, CA 92127
Key Words: IP-485®, legacy, industrial, automation, control, distributed, intelligence, network,
infrastructure, Serial, migration, IP, Ethernet, upgrade, cloud connectivity
Abstract: Traditionally, installation and systems managers have focused Suppliers of industrial
automation and distributed control infrastructure & products on reliability and predictability rather
than network efficiency or convergence. This has resulted in an install base of industrial
networks engineered, appropriately, to operate reliably in the specific application and
environment for which they were designed, closed, and operating using a myriad of physical
layer communications and language protocols. Product obsolescence, limitations in scalability of
the infrastructure and potential loss of highly skilled (contracted or on site) support all have
become high Pareto challenges to managers. In this paper, we introduce a new approach to
modernization of industrial automation & distributed control networks. It is based on managed
“migration” rather than a total “rip and replace.” Critical to the success of this strategy is the use
of a technology and product solution called IP-485® which enables a phased changeover from
legacy to modern, and thereby significantly reducing both the technical risks and project costs
incurred in the process. We show specific examples of migration within industrial networks in
conclusion to highlight both how broad and easy the transformation of legacy industrial
networking infrastructure can be with IP-485®.
I. Introduction
Industrial Automation Networks & Distributed Control Systems control and automate the
operations of machines, devices, and sensors that manufacture products on factory floors; or
perform processes within complex and distributed intelligent systems. In most cases they almost
always operate in some type of harsh environment and are often up and running almost
continuously during all three shifts in a day. Traditionally, therefore, systems managers have
focused Suppliers of industrial infrastructure and products on reliability and predictability rather
than on network efficiency or convergence. This has resulted in an install base of industrial
automation and control networks that are engineered to operate reliably in their specific
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application and environment, closed, and operating using a myriad of communication types and
protocols (Proprietary & Open). Product obsolescence, limitations in scalability of the
infrastructure, and potential loss of highly skilled (contracted or on site) support all have become
high Pareto challenges to network and systems managers.
Further, the continued move of services to the “Cloud” and a view that everything can be
modeled and implemented “as a Service” convergence between industrial networks and the
Corporate IT Infrastructure has become a key driver of modernization. The industrial networking
market is going through a transformation as a result in the drive to modernize and connect the
legacy communication infrastructure to the corporate network and deliver Cloud-based services
to increase productivity and reduce operating costs.
Modernization of legacy industrial networking faces several challenges. First, any
approach based on a complete rip and replace of the cabling infrastructure is unlikely to have
broad resonance across the industry due to the excessive capital costs, long down times and
significant technical risks involved in the project. On the other hand, the performance and
reliability challenges of using wireless technologies operating in harsh environments conflict with
the need to maintain low and predictable network latencies and high uptime. Secondly,
integration of the legacy infrastructure to the corporate network is an involved process that
combines solving technical issues as well as streamlining policies and procedures. As a result,
industrial network managers are often at a loss as to how best to design their modernization
program, and how to manage the technology changeover.
In this paper, we propose the application of a technology and related products called IP-
485® for the rapid and reliable modernization of industrial and distributed control network
infrastructure. We demonstrate that the technology alleviates several key difficulties currently
faced by network managers enabling them to think of modernization through “migration,” rather
than only a “rip and replace.” In particular, IP-485®:
- In “Real Time” Transforms Legacy Copper to operate as if it were a CAT 6 cable thus
allowing new advanced IT operations and applications without impacting legacy
functionality.
- Addresses product obsolescence issues in legacy networks, and puts in place the initial
infrastructure support required for the implementation of a technology changeover.
- Enables the design of migration strategies that describe how networks can be gradually
stepped through a phased modernization program.
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- Enables seamless convergence of the industrial & distributed control network to the
corporate IT in each migration phase, and the delivery of services to those upgraded
portions of the network.
Challenges in the Modernization of Industrial Networks
To explain the solution we have utilized an example Industrial network within a local
environment which typically can be described using a three level architecture (Figure 1). At the
highest level within a local industrial facility, there usually is a connection or connections of the
entire plant infrastructure to the corporate network. Using this connection, the corporate network
has the ability to connect to a select number of “servers” that are programmed to collect certain
plant data critical to the corporate Enterprise Resource Planning (ERP) system. Generally,
information collected is restricted to inventory and material flow, and utilized using a variation of
a “Just in Time” model to exercise supply chain. The corporate network, in cases where
modernization is already underway, may also have the ability to manage production in limited
ways.
Figure 1: Typical Industrial Network
The second level of the industrial automation architecture, and perhaps the most
interesting for IP-485® is called Supervisory Control and Data Acquisition (SCADA). It consists
of the “brains” of the actual industrial network and schedules and commands all of the machine
control and sensor data acquisition tasks. In a sense, it runs the minute-by-minute operations of
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an entire factory or overall distributed network installation. The command and communication
protocols used by SCADA controllers to run the factory are many times closed and or
proprietary. Newer SCADA controllers are equipped with RJ-45 ports and communicate via IP
protocols with the server and the corporate network. The final level consists of Remote I/Os
(RIOs) and Programmable Logic Controllers (PLCs). RIOs are used to facilitate the
communication between SCADA controllers and PLCs, and the latter, in turn, actually execute
the control programs that run machines and acquire sensor data at the edge. For this paper, we
will assume RIOs and PLCs use Serial communication.
Modernization of industrial networks require a changeover of SCADAs and PLCs from
serial communication and related language protocols (proprietary or open) to IP protocols,
which in turn facilitate the seamless integration of the corporate network all the way to PLCs and
to sensors all the way at the edge. The primary challenge in the transformation is the “rip” of
existing wiring infrastructure that connects the SCADA to the RIO and PLC, and its
“replacement” with structured cabling as this necessitates a shutdown of entire factory lines or
operational segment over a significant period of time. In addition, since IP communication is
specified to Long Range Ethernet (LRE) distances of 100m (which is often much less than the
specified bus length of the legacy serial system), there would have to be network design
considerations to select Ethernet Extender products that can extend the range of
communication beyond 100m and/or have switches at LRE distances to repeat the signals. And
finally, there are cost issues to consider as well. Industrial structured cabling for IP
communication is very expensive, and a project involving the deployment of cabling in an
industrial environment is labor intensive and requires much planning. As a result, the
transformation of industrial networks is burdened by high technical and project risks and high
costs as well as the loss of revenue due to downtime.
In this paper, we argue that the need to modernize industrial networks has moved to a
point of criticality due to the confluence of three secondary factors. The first relates to product
obsolescence. Many OEMs and product manufacturers in the industrial market are facing
significant challenges from their component suppliers who have announced End of Life (EOL)
on their older chipsets. This is manifesting itself in a wave of product obsolescence
announcement from major industrial manufacturers which will begin to impact the industrial
networking infrastructure in the coming years. Many of these manufacturers have offered only
IP-enabled controllers and other Edge devices as alternatives to the older products facing EOL.
This forces facilities and network managers to accelerate the transformation of their current
infrastructure. Second is due to a push to make ubiquitous Human Machine Interface (HMI)
panels that supervisors can use to monitor production flow, perform a process, control a device,
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or respond to alarms. While the ultimate vision of this from a consumer perspective would be to
have the HMI integrated as an App on a Smart Phone, which can be done, the approach that is
prevalent is to place a number of HMI panels throughout the network capable of interacting with
specific SCADA and PLC controllers and performing the necessary monitoring and alarm
response functions. These panels are IP-enabled and need to be tightly integrated with the
industrial network infrastructure, which is serving as an additional impetus for managers to
consider modernization of their infrastructure. And the third is the integration of the industrial
network to the corporate IT infrastructure for a variety of services to be deployed and utilized to
better manage production and process flow (especially in a multi-facility manufacturing
operation or distributed control network), to improve efficiency, safety, reduce overall costs, and
deploy new applications.
In this paper, we introduce a technology called IP-485® and describe how it can be used
to transform “functional” legacy industrial network infrastructure using a phased migration
approach. It achieves all of the goals for facilities, plant, control and network managers as if
CAT 6 were deployed instantly; but with reduced technical and project risks, reduced costs, and
minimal downtime all while maintaining the existing functionality already in place.
IP-485® Technology
At the heart of the phased migration strategy is a technology called IP-485® which
enables the simultaneous transport of IP data and Serial data over the same wiring
infrastructure (twisted or untwisted pair, current loop, specialized industrial cabling, proprietary
cabling, etc.), even in the presence of significant conducted and radiated noise in the medium.
The foundation of this technology lies in algorithms called Dynamic Adaptive Channeling which
decide in real-time how to encode data payloads into communication frequency channels, so
that Quality of Service (QoS) can be maintained at all times subject to channel constraints. The
algorithm starts with a full spectral sweep and a determination of the Signal-to-Noise Ratio
(SnR) properties across the entire channel. To make the problem computationally elegant, the
algorithm divides the overall communication channel into Orthogonal Divisional Frequency
Multiplexing (OFDM) sub-channels and conducts the SnR analysis at the baseband associated
with each sub-channel (shown in Figure 2). This helps determine available sub-channels at a
given Quality of Service (QoS), which in turn maximizes the utilization of usable channel
capacity.
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Figure 2: Dynamic Adaptive Channeling
Adaptive Channeling is a real-time channel optimization policy and permits the
deployment of robust communication networks in harsh environments. The algorithm is robust
to white noise in the channels which degrade the communication bandwidth, and colored noise
in the channels arising from factors such as EM interference from nearby operating equipment.
In addition, it automatically discovers usable communication channels regardless of the type,
gauge or topology of wiring used. As an example, IP-485® operates successfully on 18-gauge,
twisted pair, multi-drop wiring, untwisted pair, simple daisy-chained wiring and other specialty
cabling. Communication is robust to collisions arising from other applications currently using the
channel, which are seen as interferences in channel analysis. This enables the technology to
implement multiplexed channel access across applications at the physical level. In addition, if
more than one OFDM sub-channel is available for communication, the technology enables the
implementation of a Bus consisting of sub-channels that run concurrently, each of which may be
multiplexed between applications.
The second set of properties manifest in PCN’s IP-485® relates to real-time network
management at the application level. Concurrent with the adaptive channeling algorithm, we
also implement a real-time communication engine that enables the delivery of serial data (that is
multiplexed with IP data) using critical latency requirements already in place, encoded in jitter
free, at copy-exact waveforms, regardless of wiring type, noise, interference of other
considerations that affect signal integrity. Further, we also implement a network engine that
enables network configuration and management in real-time. For example, in a Master-Slave
configuration, the concept of a Floating Master may be implemented using the engine. Further,
data payloads with high priority may be queued and delivered with very low latency across the
network. Network data is not impacted and remains intact.
IP-485® Networks
Figure 3 shows a sample network established using IP-485® network products. It
consists of a Server that is connected to the Corporate Network via an ISP line (T1, Fiber or
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Satellite) using a standard CAT 5/6 connection. It is also connected to serial network(s) on its
Low Frequency (LF) Bus(es). The PCN Single Channel Server (SCS) accepts a single serial
network connection (shown in Figure 2), while the Multi-Channel version (MCS) permits the
integration of multiple serial networks, each on a distinct wiring infrastructure. The Server then
transports both IP data and Serial data on the same output channels, repurposed to be called
the Broadband (BB) Bus. The SCS has a single BB Bus, while MCS would have many separate
BB Buses as Serial network inputs on the LF Bus. In this architecture, the Shared Wire multi-
channel, multiplexed access bus is implemented on the repurposed BB Bus wiring.
Each IP-485® Server is connected to one or more PCN Single Channel Clients (SCC)
on the BB Bus. A SCS is capable of receiving multiple IP device inputs driving numerous SCCs
for smaller networks to multiple addressable sub-networks; while a MCR has the capacity to
drive many SCCs across many different wiring infrastructures for local area networks and
distributed networks. Each SCC has a BB Bus port that is used to connect to its Server. On the
output side, serial networks can be connected to its LF Bus allowing continuation of the serial
network to its standard distances; and IP devices can be connected to the 3 RJ-45 ports
available on each client. Networks designed with MCSs and SCCs have the ability to integrate
up hundreds of IP Edge devices, and run many separate serial networks, each potentially
having different protocols. In each case, the IP network co-exists with the Serial, or legacy
protocol network without any impact on the performance of one network from the other.
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Figure 3: IP-485® Network Architecture
Migration Using IP-485® Networks
Figure 4: Typical SCADA – PLC Architecture
Consider a typical industrial network segment between a SCADA and the RIOs and PLCs
that it controls downstream using some dedicated cabling infrastructure. The SCADA controller
communicates with all of the devices using one of a variety of physical level serial
communications (RS-232, RS-422, and RS-485) and related communication or language
protocols (e.g., Modbus, Can, Fieldbus, DH, Profibus, Etc.) The cases below discuss a local
area RIO but also can be applied to Distributed I/O through network design and placement of
IP-485® modules. We will consider five Use Cases to discuss the power of IP-485® in
developing migration strategies that accommodate new requirements on the infrastructure
without any wiring change-outs:
1. One or more of the PLCs utilized in the segment fails but cannot be easily replaced
since it is beyond EOL or facing obsolescence, and the only option is to go to a newer
IP-enabled version of the product.
2. There is a need to integrate an IP-enabled panel that can be used to monitor the status
of one of more of the PLCs in the segment from a location other than the monitors
attached to the SCADA controllers.
3. There is a mandate to change all PLCs in the segment to IP-enabled PLCs to increase
the cyber security of the entire SCADA infrastructure.
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4. There is a need to integrate the SCADA controller to the corporate network
5. There is pressure to integrate new IP-enabled devices such as cameras for plant safety
and physical security.
Product Obsolescence:
Figure 5: Dealing with Product Obsolescence using IP-485®
Consider a scenario where the PLC at the end of the segment connected to a RIO and
the PLC before it have failed. The manufacturer has announced EOL and has recommended a
newer version that is IP-enabled as a replacement. It is no longer supporting the older version,
and limited amounts of refurbished units available through distributors are priced at a significant
premium. In this case, but splitting the wiring at the head-end, connecting the output of the old
SCADA controller to the LF Bus of a SCS, and the other end of the split wiring to the BB Bus of
the SCS, we have immediately re-purposed the existing wiring to become capable of carrying
both the serial data from the SCADA controller, and accommodate the transport of IP data. As a
second step, we connect either the IP of the old SCADA controller (or, as shown in the figure,
connecting a new IP SCADA controller in the event the old controller is not IP-enabled), at the
head end to the RJ-45 port of the SCS. Following this, if we connect a SCC at the location
where the failed PLCs have to be replaced with IP PLCs (as shown in Figure 5), we have
enabled connectivity between the new PLCs and the SCADA without any need for structured
cabling. This not only solves the immediate challenge faced by the facilities manager by
addressing the replacement of the failed PLC that are past EOL, it also provides a path to the
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migration of the infrastructure into a full IP-enabled network - gradually, in a phased manner,
every PLC on the BB Bus can be switched to an IP PLC.
IP Panel Integration:
Figure 6: Integrating an IP Panel to the Network using IP-485®
The second application considered is one where the integration of an IP panel is
required for the facilities manager to monitor and control the production line directly from the
panel using its HMI interface functions. In the example shown in Figure 6, the integration is at
the end of the segment, and can be implemented by, once again, splitting the wiring at the
head-end, connecting the output of the old SCADA controller to the LF Bus of a SCS, and the
other end of the split wiring to the BB Bus of the SCS. As a second step, we connect the IP port
of the old SCADA controller at the head end to the RJ-45 port of the SCS. Following this, we
connect a SCC at the end of the segment and simply connect the IP panel to its RJ-45 port.
This completely integrates the panel to the SCADA controller without any new wiring, and, as
before, provides a path to the migration of the infrastructure into a full IP-enabled network.
Integrating the SCADA Controller to the Corporate Network
With IP-485®, getting the network segment connected to the corporate network is also
pretty straightforward. As shown in Figure 6, we begin by splitting the wiring at the head-end,
connecting the output of the old SCADA controller to the LF Bus of a SCS, and the other end of
the split wiring to the BB Bus of the SCS. As a second step, we locate an IT closet along the
network segment that can establish a network connection to the corporate network. Then we
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deploy a short CAT 5/6 cable run from the closet to a new IP SCADA and connect it to the BB
Bus using a SCS. This completely integrates the older SCADA controller with the new IP
SCADA controller, and in turn gets integrated into the corporate network.
Figure 7: Integrating SCADA to the Network using IP-485®
And finally, integration of other Edge devices can be achieved using the architecture
shown in Figure 5 by replacing the IP panel with cameras, access control panels, and other IP
devices. As before, this also provides a migration path for the legacy infrastructure.
Scalable, Reliable, & Secure
In any legacy system, whether local or distributed; IP-485® systems are scalable
allowing the placement of devices where needed allowing the accommodation of data at any
length ensuring the transport and access of IP data networks in areas traditionally not thought
practical. IP-485® products should be functionally viewed as intelligent or smart wire as if CAT 6
were installed but with added features and benefits unattainable with simple wiring or cabling.
Importantly, IP-485® products also allow unique reliability and security features. For
added reliability, above and beyond Dynamic Adaptive Channeling algorithms operating in real
time, IP-485® products also have unique fault detection and squelching functions that isolate
any network or connected device fault, keeping it localized so that the fault does not bring down
any aspect of the network.
Finally, security is a huge issue within industrial networks and although IP-485®
products transport the security measures from the connected devices for which it is transporting
just as a CAT 6 cable would; IP-485® products also have additional security and encryption
algorithms available to network managers adding additional levels of security and encryption
translating to an even more secure network. With IP-485® network owners now have the ability
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to utilize proprietary algorithms and encryptions on top of existing standardized algorithms
allowing unique security features for applications. These can be deployed across the entire
network or in specific parts.
Conclusion
In this paper, we have presented a technology called IP-485® and have described how it
can be deployed to easily, rapidly, securely, reliably, and cost effectively transform existing
legacy industrial network infrastructure into one that can support IP-enabled devices that are
connected to the Cloud.
The technology can be applied successfully in a variety of local and distributed network
configurations. IP-485® operates using numerous types of physical layer communications and
data protocols (open and proprietary) already operational within Legacy Industrial systems. It
operates on twisted and untwisted wiring of many types in standard networking topologies along
with critical daisy chain or multi-drop topologies. It allows the very easy placement of Ethernet
within legacy industrial settings and hard to reach locations without impacting existing
communication network or business operations within harsh installations and environments;
either inside or outside. This allows managed migrations as needed in critical locations.
The products have been developed specifically to allow migration and IP connectivity
within Industrial, Building, Oil/Gas, Energy and Transportation operations that require real time
reliability and security; but that also need to continue to modernize to open standard IP enabled
networks to achieve new functionality, additional security, new applications, remote network
management and other IT functionality such as virtualization and other forward looking
functionality such as (SDN) Software Defined Networking and big data storage and analytics for
the world’s critical manufacturing, energy, transportation, and overall critical living infrastructure.
IP-485® provides a secure and scalable migration path by transforming functional legacy
copper to become simultaneously operational as if it were a CAT 6 cable – at any length.
Additionally, IP-485® products are strategically designed to plug and play into “industrialized”
environments to self-configure and rapidly deploy IP enabled Ethernet anywhere into hot-
pluggable networks while also providing critical reliability and security functionality both within
the local area, but all the way from the Cloud.
By combining the IP-485® “copper transformation” with “strategic product design”; IP-
485® allows a managed and cost effective way to rapidly upgrade critical legacy systems of
yesterday to the advances in IT today without the traditional costs and risks. It provides an
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economic path for network owners to be able to accelerate their network advances with less
CapEx budget for installation and integration; while reducing integration risk due to elimination
of shutdown and by keeping business and network operations in place while the migration takes
place.
IP-485® products interface seamlessly with Zigbee, Wi-Fi, 4G LTE, Fiber and other
communication and network types. IP-485® products are being deployed today within Industrial
Automation networks, Oil and Gas networks, Building Automation networks, and Transportation
networks. IP-485® works with standard digital networking products by manufactures like Cisco,
Juniper and others; while seamlessly operating with Industrial products from manufacturers like
ABB, Rockwell, Siemens, Schneider Electric, GE, Honeywell and of course working on standard
and proprietary cabling from companies like Belden, Panduit, Commscope and others.
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