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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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