INNOVATIONS
BACK TO BASICS: INDUSTRIAL CONTROLLERS
Jon Breen, Breen Machine Automation Services
Terms: PLCs, PACs and IPCs
A programmable logic controller (PLC), process automation controller (PAC) and
industrial PC (IPC) have unique features and benefits, but traits are blurring.
I
s a programmable logic controller (PLC)
always a PLC, or is it a process automation
controller (PAC) or an industrial PC (IPC)?
What’s the difference? Which one is needed for
my process or machine? Let’s start by filling in
some historical context and defining each term.
PLCs: Programmable logic controllers (PLCs)
are industrial computers used for automation and
control. A PLC system monitors inputs, makes
decisions based on its program, and controls out-
puts to run a process or automated machine. This
description also fits PACs and IPCs.
So what’s the difference? The truth is, there are
only very general guidelines that describe the differ-
ences, and there’s a lot of overlap.
PACs: By traditional definition, PACs are con-
sidered to be more decentralized, able to connect to
remote input/output (I/O) and other PACs. They’re
also touted as having more advanced programming
capabilities compared to a PLC’s ladder logic lan-
guage. This definition may have worked 20 years ago,
but virtually all PLCs today have these features.
A more modern definition for PAC is elusive.
The cRIO platform from National Instruments (NI)
is a good example of a modern controller with the
PAC label. It has features like a built-in field pro-
grammable gate array (FPGA) that aren’t seen on
PLCs, but what exactly constitutes a PAC? A basic
way of viewing it is a PAC is a PLC with a couple
extra bells and whistles. Some of these extra bits
will be adopted by the PLCs of tomorrow, which
confuses the issue further.
IPCs: IPCs, like their non-industrial counterparts
run operating systems (OSs) like Microsoft Windows
or Linux, giving them access to nearly endless soft-
ware tools and connectivity options. Early IPCs were
different from PLCs, bu like PACs, the technology is
converging. Devices that run Windows, but still look
and feel like PLCs, have been around for years. For
example, Beckhoff Automation sells IPCs that mount
in a rack with I/O cards and can be programmed with
ladder logic. It’s possible Microsoft Windows will be
the norm in 20 years and the term “PLC” will swallow
up IPC just like it did with PACs.
PLC, PAC, IPC use vs. emotion
The terms PLC, PAC, and IPC are as much about
branding as about capabilities. Each one has all the
power to incite emotion that any logo ever did.
PLCs may feel comfortable, predictable, known,
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reliable, safe, boring, limited. PACs may feel futur-
istic, exciting, scary, unknown or powerful. IPCs
may feel unstable, unreliable, powerful, stable or
reliable.
Emotional responses vary depending on the indi-
vidual, and may be extreme or dogmatic. For example,
a person whose primary goal is to keep a production
facility running may view everything in an extreme-
ly conservative way. This person may strongly prefer
the term PLC because of its feeling of known, stable,
reliable. Someone might things called PAC or IPC at
all costs with thoughts like, “PCs get viruses, break
down, require updates, etc.” and “Nobody knows how
to troubleshoot a PAC if something breaks.”
None of these thoughts is subjectively true
across all devices with those names. In fact, many
devices could easily be classified under two or all of
those names. This is emotional rather than rational
thinking; manufacturers know their audience and
play to that. For example, a manufacturer targeting
a user base in production will use the term “PLC”
to describe even its most advanced offering that fits
the definition of PAC. A manufacturer focusing on
R&D, test and measurement, and datalogging will
choose the term “PAC” even for its simplest offer-
ings. These labels are chosen as much for an emo-
tional branding effect as they are to describe a
technical difference.
Controller to fit the application
So are PLC, PAC, and IPC differences?
Lack of clarity doesn’t have to get in the
way of controller selection. Consider goals
and find a controller to suits the applica-
M More
INNOVATIONS
KEYWORDS: PLC, PAC, IPC
tion. What is locally supported? What do
others use in similar situations? Know that The terms PLC, PAC and IPC imply
different things and there is overlap.
each term is generally marketed towards
When it comes to general capabilities,
certain industries and certain types of a PLC, PAC and IPC can do many of
people. Understanding the target audi- the same things.
ence of a term and your position might Some situations and applications suit
help narrow down the options, despite one over others.
vague definitions. Beware of emotional ONLINE
responses that affect decisions. Focus on Read this article online at
specific benefits and capabilities. ce www.controleng.com for more from
Breen Machine Automation Services.
Jon Breen, founder/owner, Breen Machine www.controleng.com/control-systems/
Automation Services, a Control Engineer- plcs-pacs
ing content partner. Edited by Chris Vavra, CONSIDER THIS
associate editor, Control Engineering, CFE What criteria do you use when
Media, cvavra@cfemedia.com. choosing among a PLC, PAC or iPC?
CONTROL ENGINEERING May 2020 • 53