A supplement to PLANT

ControlENGINEERING
Engineering
and Control Engineering magazines
PLANT ENGINEERING magazines
 Quality enclosures and accessories for less!
Hubbell/Wiegmann Enclosures NEW! Enclosure Accessories from
Shop from our extensive selection of over 2,300
NEMA rated highly reliable and quality-built STEGO Ecoline LED Enclosure Lights
Hubbell/Wiegmann enclosures available at great Starting at $43.00 (025423-13)
prices and with customer service you will only
• No special cables required, simply plug straight into the
find at AutomationDirect. dual cage clamps (shown in picture below)
• Daisy chain additional lights using dual cage
clamp connection
• New clip mount allows for light to be rolled
to different angles or be removed for
spot-lighting
• Available with ON/OFF switch or motion sensor
• Models available with screw or magnet mounts

starting at:
$6.50
SA100SL
STEGO Filter Fan Plus
Starting at $60.00 (018809-40)
• Enclosures to fit any purpose, application or
installation type • Available in two different airflow systems; FPI for intake fans,
or FPO for exhaust fans
• Materials: Stainless and carbon steel, aluminum,
and fiberglass • Easy and fast installation using a true “no screw” 6-position
ratchet mounting system to firmly and securely mount the fan
• NEMA ratings of 1, 3, 3R, 3S, 4, 4X, 6P, 12 and 13
• Easy filter access
via hinged cover
Integra Polycarbonate Enclosures • UV resistant, flame
Our top-quality polycarbonate NEMA enclosures retardant, and
manufactured by Integra are excellent for a wide impact resistant
range of indoor and outdoor applications.

starting at: STEGO Hose-Proof Hoods

$27.50 Starting at $114.00 (086700-00)
P4043-P10
• Designed to increase protection class
to UL Type 4X and to protect STEGO
filter fans
• Protects against water projected by a
hose and in applications with harsh
• Non-corrosive and non-conductive NEMA enclosures environmental conditions
• Easy to install and modify for component installation • Stainless steel hood that is easy to
• NEMA ratings of 1, 2, 3, 3R, 3S, 4, 4X, 5, 6, 6P, 12 and 13 install and remove for cleaning

YEAR
1 Research, price, buy at:
www.go2adc.com/enclosures

Order Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation
Contents
A4 Providing circuit
protection for safety
When correctly selected and applied, circuit breakers,
fuses, and other protection components can help keep
workers safe from injuries and machines from damage.

A4
A10 Implementing remote
technical training
By using an Industrial Internet of Things (IIoT) gateway,
or a remotely controlled PC, critical how-to skill-based
training can be made available to engineering students
anywhere there’s an internet connection.

A10
C OMMENT
Protecting circuits, training remotely

E
lectrical safety typically is considered the
purview of electrical engineers and elec-
tricians. However, the cover story in this
issue is applicable to anyone who works
around electricity—including those who work in
automation, instrumentation, and control.
The author of the cover story examines com-
mon electrical safety scenarios and suggests
Jack Smith ways to protect personnel and machines. He
Editor writes, “Electrical protection in all forms is
critical for the protection of personnel, but it’s
often overlooked. Properly protecting a system
or equipment is a key step in reducing costly
downtime and equipment damages.” He points
out that short-circuit current and overload pro-
tection guards against electrical system dam-
ages, overloads can shut down power during
construction, and during maintenance, incorrect
wiring or a misplaced tool could cause current-
limiting devices to activate.
In addition, the author explains the differ-
ence between branch-circuit and supplemen-
tary-protection devices: “Branch circuit-rated
devices protect the wires, and supplementary
devices provide additional protection, but they
are not sufficient to protect the equipment or
load exclusively. Supplementary devices often
are used for lower load equipment, internal
loads, or as a simple additional disconnect-
ing means.” According to the author, these
supplementary protective devices are specified
to protect control circuits, programmable logic
controller (PLC) input/output (I/O), contactor
coils, and relays internal to a panel or piece of
equipment.
Technical training is always important to
keep engineers and technicians up to speed
on rapidly changing technology. The second
story in this issue explains how to accomplish
this remotely. According to the author, using an
Internet of Things (IoT) gateway, or a remotely
controlled PC, critical how-to skill-based train-
ing can be made available to students any-
where there’s an internet connection.

ON THE COVER Regulations and methods to protect personnel and machines from shock, burns, and fires can be found in NFPA 70—2017: National
Electrical Code (NEC). Courtesy: AutomationDirect

Applied Automation June 2018 • A3

 C o v e r s t o ry

Providing circuit
protection for safety
When correctly selected and applied, circuit breakers, fuses, and other protection
components can help keep workers safe from injuries and machines from damage.

By Brent Purdy, PE For example, during a construction project, a large

AutomationDirect circuit breaker in a plant tripped during operation. The

M
breaker did its job, quickly ending a short-circuit condi-
tion, but it cut off power completely to an entire building.
ost engineers, technicians, and factory At the time, it was not known which of the many building
workers have a story about industrial loads caused the breaker to trip, so it was difficult to
injuries, such as shock or burns that find the source of the problem.
occurred on the manufacturing floor. Eventually, the root cause was found to be a shorted
While most incidents happen during brake on a large motor. What made the problem difficult
construction, maintenance, or testing, to locate was the load-shedding breakers used to safely
they can occur during normal operations as well. There limit generator loads by dropping some of the load. These
are a variety of scenarios where shock or burn inju- load shedding breakers re-close with a delay, complicat-
ries can occur, but most can ing troubleshooting the issue.
be prevented by using best While it contributed to the
design practices and following Circuit protection is outage, this breaker continued
safe operating procedures. to operate and protected the
There are many causes for critical to protect a machine people and equipment during the
electrical fires and other inci- troubleshooting and diagnostics
dents, with various prevention process. After the shorted brake
methods for each type of prob-
from currents greater than was found and repaired, the
lem found in the National Fire long-term solution was to coordi-
Protection Association (NFPA) the machine or device’s nate operation of all the breakers
document, NFPA 70—2017: so that downstream breakers
National Electrical Code (NEC). current-carrying capacity. operate prior to upstream break-
A big part of electrical safety ers during low-level faults.
involves proper circuit protec- Another incident occurred near
tion, which can mitigate problems and reduce their the end of a week-long, plant-wide outage to perform pre-
impact. ventive maintenance on switchgear. As part of the re-ener-
Electrical protection in all forms is critical for the pro- gization procedure, final safety testing was done to confirm
tection of personnel, but it’s often overlooked. Properly all the buses and feeder lines were electrically isolated,
protecting a system or equipment is a key step in reduc- and not grounded or shorted together. The breakers also
ing costly downtime and equipment damages. This needed to be tested to confirm proper insulation integrity.
article examines common electrical safety scenarios, Even with all this testing, when the main site breaker
along with ways to protect personnel and machines (see was closed, it shorted out the switchgear. Later test-
Figure 1). ing revealed someone inadvertently had left a tool in
a spot where it vibrated down onto the main breaker
Problem scenarios and was not visible. Fortunately, a fast, current-limiting
Proper short-circuit current and overload protection is breaker activated and contained the incident with only
required to protect against electrical system damages. minor damage. Without the current-limiting breaker,
During construction, an overload could shut down power. the short likely would have resulted in an explosive arc
During maintenance, incorrect wiring or a misplaced tool within the switchgear, and possibly personnel injuries
could cause these current-limiting devices to activate. from fire or arc flash.

A4 • June 2018 Applied Automation

Figure 1: Regulations and methods to protect personnel and machines from shock, burns, and fires can be found in NFPA 70—2017:
National Electrical Code (NEC). All images courtesy: AutomationDirect
Safeguards from shock and fire
To mitigate incidents like the two described above and
others, NFPA 70E-2018: Standard for Electrical Safety
in the Workplace provides detailed information regarding
electrical safety and many other regulations for electri-
cal wiring and overcurrent protection. In addition, NFPA
79-2018: Electrical Standard for Industrial Machinery, dis-
cusses protection of equipment as well.
There are many requirements and guidelines to follow
to protect personnel and machines from shock, fire, and
other damaging events due to the presence of electrical
energy or electrical failures. An overview of some of the
many electrical safeguards include:
 Provide a lockable disconnect means
 Interlock doors to disconnect power
 Include safety signs
 Provide overcurrent protection
 Provide surge protection.
This article is a general safety discussion, and it’s
important to note that there are exceptions to many
requirements, with some important details not covered
due to space constraints.
Though often overlooked, disconnects on industrial con-
trol systems perform the important function of ensuring the
electrical feed circuit to a machine or system is completely
de-energized to protect maintenance and operations per-
sonnel from electrical shock. Regulations require all power
to the equipment must be shut off, locked out, and tagged
out before servicing. Disconnects provide this functionality.
NFPA 79 requires a disconnecting means for isolat-
ing the supply of power to a machine. While this can be
as simple as a plug and a safety sign, most machines
use other methods. Typical disconnect methods are UL
98-rated fused/non-fused switches or a UL 489 circuit
breaker. Usually there is just one machine electrical
supply circuit and all power should be switched off by
opening the disconnect for this supply. This should be
labeled as the “Machine Power Supply Disconnect.” If
multiple sources of power are present, signs must clearly
state the exceptions and the proper procedure to remove
power from a machine.
This disconnect should be mounted in or next to the
main control system enclosure. If the main control system
enclosure contains common ac voltages such as 120 Vac
or 480 Vac, or if any voltage greater than or equal to 50
Vac or 60 Vdc is present, the door should be interlocked
to the disconnect. To reduce the risk of electrical shock,
the door shouldn’t open if the disconnect is on unless it is
defeated by qualified personnel using a specialized tool.
While a disconnect with a door interlock is the best-
practice way to remove the electrical feed from a control
panel, other methods such as door locks and keys, and
guards protecting personnel from direct contact with haz-
ardous voltages, are allowed. Regardless of the method
used to disconnect power or protect personnel, safety
signs on the enclosure should define proper procedures
for removing power.
Branch circuit versus supplementary protection
Circuit protection is critical to protect a machine from
currents greater than the machine or device’s current-
carrying capacity. Proper electrical protection is the key
to safely removing the effects of dangerous overcurrent
due to short circuit, overloads, ground faults, voltage
Applied Automation June 2018 • A5
 C o v e r s t o ry
transients from switching surges, and other abnormal con-
ditions (see Figure 2).
To provide this protection, it’s important to understand
branch circuit protection versus supplementary protection.
In general, branch circuit-rated devices protect the wires,
and supplementary devices provide additional protection,
but they are not sufficient to protect the equipment or load
exclusively. Supplementary devices often are used for
lower load equipment, internal loads, or as a simple addi-
tional disconnecting means.
Figure 2: Overcurrents, short circuits, and ground faults are some
of many causes of electrical fires.
There are many general requirements, wiring prac-
tices, and grounding and bonding techniques to protect
machines and personnel. To provide overcurrent pro-
tection, branch-circuit short-circuit, and ground-fault
protective devices, supplemental overcurrent protective
devices are needed.
In general, UL 489-labeled devices provide branch cir-
cuit protection, and UL 1077-labeled devices provide sup-
plementary protection, with NEC Sections 100, 430, and
409 providing detailed definitions (see Figure 3). Outside
the U.S., there are different, but related, standards.
Most electrical circuits start with branch circuit devices,
such as an appropriately labeled circuit breaker or fuse.
These devices protect against fire and electrical shock by
limiting current flowing through wires and provide a means
to remove electrical power during equipment service.
Branch circuit protection does not necessarily protect
a load such as a power supply, a PC, or a programmable
logic controller (PLC). To provide this protection, supple-
mentary protection fuses and circuit breakers are used.
Supplementary protection provides additional equipment
protection where branch circuit protection is already pro-
vided or not required.
Breakers and fuses
UL 489-rated miniature circuit breakers and molded
case circuit breakers often are used for branch circuit
protection of feeder circuits downstream from a main dis-
connect, or for motor circuits. They are available in sizes
ranging from fractional amps to about 800 amps, often
with miniature form factors, and come in a variety of frame
sizes, with 1- to 3-pole configurations.
These devices use thermal and magnetic trip units to
trip/open the breaker when either an overload or a short
A6 • June 2018 Applied Automation
circuit is detected. Overloads are caused by excess cur-
rent slowly heating wires and equipment. Breakers protect
circuits from these dangerous events by sensing the heat-
ing effects of an overload condition using the thermal ele-
ments of the trip unit. On the flip side, massive damage
of a short-circuit fault will occur in a fraction of a second.
In this instance, the breaker’s trip unit senses this fast
change in current via magnetic field sensors and initiates
the protective function.
Some breakers include current-limiting designs to provide
fast operation during short circuit events. This reduces the
let-through energy, which can damage the equipment or
wiring. They can have fault current interrupt ratings in the
10 to 100 kA range. Different trip curve characteristics also
are available for low inrush circuits such as resistive loads,
and for high inrush inductive and other loads. Breakers with
these special curve characteristics provide the best protec-
tion, and also reduce nuance tripping.
Fuses usually are a more cost-effective method of over-
current protection. They work well in applications where
high fault current exists, and are commonly used to protect
transformers, power supplies, and motors. Many branch
circuit protection fuses are current-limiting and available
with high interrupting ratings up to 200 kA. Fuses are
available to meet UL and NEC code requirements and
include time-delay and fast acting types. These fuses don’t
wear out as there are no moving parts as with a circuit
breaker, and contamination by dust or oil is unlikely.
A fuse’s biggest disadvantage is the need for replace-
ment after operation, unlike a circuit breaker, which can
typically be reset. Also, fuses inherently increase the
chance of single phasing. Thus, while a fuse protects the
system from a fault, equipment can be damaged by a sin-
gle-phase condition, so key equipment should be equipped
with blown-fuse detection phase monitoring devices.
While breakers are becoming more economical and
their protection technologies are improving, fuses always
have been the gold standard for fast interruption of very
large amounts of current. However, many users are will-
ing to pay more for the capabilities breakers provide,
especially electronic trip and current limiting, because of
the downtime required to replace fuses. The logistics of
stocking, finding, and replacing a blown fuse weigh heav-
ily in these cases.
Supplementary protectors comply with UL 1077. They
are not built, tested, or certified for branch circuit protec-
tion. These devices supplement the branch circuit protec-
tion that must already be in place. These supplementary
protective devices are specified to protect control circuits,
PLC input/output (I/O), contactor coils, relays internal to a
panel or piece of equipment, etc. They have much tighter
spacing than UL 489 devices, and they also have lower
interrupt ratings, usually less than or equal to 10 kA.
Whether it’s a circuit breaker or fuse, or branch circuit or
supplemental protection, users must pay attention to oper-
ating conditions, such as high inrush current, maximum

Solution Center evolves
into a one-stop knowledge shop
Y
askawa’s Solution Center is
a portal to help customers
get specific help with product
issues. It’s evolved into much
more than that, as Cris Franco, Yaska-
wa’s Customer Technical Support Man-
ager, discusses:
Q: What was the genesis for Yaska-
wa’s Solutions Center?
FRANCO: There were some fundamen-
tal reasons we wanted to create a Solution
Center that included providing a better
search experience at Yaskawa.com, to
provide experiences tailored to our
customers’ search needs and to central-
ize various repositories we had within
our organization to create a one-stop-
shop for all things Yaskawa. Above all
though, Yaskawa understands that in
the current age and times we live in, us-
ers of our products do not want to wait
in a phone queue to speak with some-
one that can answer their question(s),
nor do they want to send an email and
wait for a reply.
Yaskawa also recognizes that as Mil-
lennials begin to enter the workforce,
it’s going to change from a “want” to
an expectation. Yaskawa’s answer and
preparation for this expectation is the
Solution Center.
Q: What makes this tool so valu-
able for Yaskawa customers?
FRANCO: Yaskawa products are highly
configurable and easily adaptable in al-
most any industrial or commercial au-
tomation application. Because of this,
our users may be intimidated by our
product manuals that contain a lot
of important details. The Solution
Center bridges the gap between
our technical manuals and what
Advertisement
they are trying to do or what problem
they’re trying to resolve.
The Yaskawa Solution Center pro-
vides various things like step by step
instructions for troubleshooting fault
codes and how to resolve them. It pro-
vides help with configuring a Yaskawa
product into a new application. Users
can get answers to questions they may
have about installing or upgrading a leg-
acy product. Yaskawa’s Solution Center
provides a way to easily find a document
or manual required to get their job done.
Q: For those visitors to the site
who are not yet Yaskawa custom-
ers, how can they most effectively
utilize the information? How does
the search function work if you
don’t know a specific product, for
example?
FRANCO: The Yaskawa Solution Cen-
ter uses natural language search to
find relevant content. It’s been referred
to as a Google for all things Yaskawa.
Visitors that are not yet customers of
Yaskawa can use our Solution Center
as a learning center. They can perform
searches for common automation terms
such as overvoltage, overload, overcur-
rent, speed search, and learn what they
mean or how they’re used.
Q: A review of the site at https://solu-
tioncenter.yaskawa.com shows that
you’re not only answering questions,
but your customers also are offering
suggestions for future product line
extensions. Was that a surprise, or
did you anticipate that kind of inter-
action with your customers?
FRANCO: I’m glad you noticed.
The Solution Center includes a
crowd-sourcing feature which allows
visitors to provide feedback on just
about any document or page within a
document for the purpose of contin-
uous improvement. Visitors can let us
know if they recommend we add more
information about a specific topic or
if they feel the content is incorrect.
It allows us to keep our content rele-
vant based on customer demand and
usage.
Q: Is there anything the Solution
Center doesn’t know?
FRANCO: What the Solution Center
doesn’t know is that we have a lot in
store for it. We’ve only just begun.
We plan to make future experiences
seamless to yaskawa.com visitors. We
are looking forward to a day when our
website will be self-proactive by antic-
ipating and predicting what our exist-
ing and future customers need
before they even know they need
it. It will be the perfect place for
all automation solutions.
 C o v e r s t o ry

amperage and voltage, maximum short circuit currents,

and other factors. Fuses usually offer better protection due
to superior current limiting, but they must be replaced after
operation, which can increase downtime. Circuit breakers
are quick and easy to reset, but even a current-limiting
circuit breaker will not operate as fast as a properly sized
and selected fuse.

Providing safety from surges

When it comes to shock or fire safety, surge suppression
often is overlooked, but power surges cost U.S. compa-
nies more than $80 billion a year. Surge protection devices
(SPDs) can help prevent these losses by shielding against
small power spikes that damage equipment over time and
also can provide defense against less frequent but more
serious major power surges.
Approximately 20% of power surges come from lightning
strikes, while the other 80% typically originate from within
a plant or facility from motors starting and stopping, and
from other high inductive loads.
While it always has been good design practice to include
surge protection, the NEC has been adding areas where
surge protection is required. SPDs have been increasingly
seen as crucial for protecting emergency systems and
equipment. A partial list of areas when surge protectors
are now required by NEC 2017 includes:

n Article 670.6: Industrial machinery with safety interlock

circuits shall have surge protection installed
n Article 695.15: A listed surge protection device shall be
installed in or on the fire pump controller
n Article 700.8: A listed SPD shall be installed in or on
all emergency systems switchboards and panelboards
n Article 708.20: Surge protection devices shall be pro-
vided at all facility voltage distribution levels.
Type 1 surge suppression typically is installed on the
line side of a disconnect, protecting equipment from light-
ning, but can be used anywhere in an electrical circuit.
Type 2 surge suppression is installed on the load side,
protecting from motor starts and stops, and similar surges.
Type 3 surge suppression is installed at the device level,
such as in power strips.
These surge devices are selected based on the supply
voltage, expected magnitude and rate of occurrence of power
surges, and the number of phases in the power circuit. They
provide inexpensive insurance from equipment damage.
PLC outputs also should be protected from surges and
overloads. Some outputs may have surge suppression
built in, which protects the output from inductive loads, but
these are not always adequate for many loads, such as
solenoids or contactors, so it’s good design practice to add
suppression at the load as this will lengthen the life of the
PLC outputs.
Inductive loads can cause a spike of hundreds of volts,
and these high voltages can damage or destroy PLC relay
Figure 3: A wide variety of UL 489- and UL 1077-rated circuit
breakers and fuses are available to protect wiring and electrical
equipment.
and transistor outputs. To provide protection, a diode can
be installed across the output coil to provide a path for the
current to flow back through the coil while the magnetic
field is collapsing, eliminating the voltage surge. While a
simple diode probably is the best option for surge sup-
pression across a dc coil, a variety of surge suppression
devices are available to protect against surges from ac/dc
loads including varistors, resistor/capacitor (R/C) combos,
and specialized transient voltage suppression diodes.
There are more than 800 pages in the NEC, so this
article only provides an overview of requirements to keep
personnel safe from electrical shock and to prevent electri-
cal fires. Using this information as a starting point and a
blueprint, additional details can be filled in from the NEC
and other sources to provide the circuit protection needed
to ensure safety in an industrial plant or facility.
Brent Purdy is the product manager for power and cir-
cuit protection at www.AutomationDirect.com. Prior to his
current position, he was a product engineer. Before join-
ing AutomationDirect in 2013, he worked as an electrical
lead and a senior engineer at Polytron, and as a system
engineer at Westinghouse Anniston. He has a BSEE from
Georgia Institute of Technology.

A8 • June 2018 Applied Automation

MOVE SECURELY INTO
THE CLOUD  %8 , /7ǫ,1
5 , 7<
8
6(&
WAGO Cloud

Microsoft
Amazon Web
Azure
Services

IBM
Other Cloud BLUEMIX
Services

IIoEATDY
R

Direct Field to Cloud Connection

with the PFC Series Controllers
• IIoT-ready with native MQTT and TLS encryption
• Built-in VPN and Firewall for increased network security
• Simplify data routing and reduce latency
• ,QWHUIDFHZLWKH[LVWLQJFRQWUROVYLDRQERDUGƮHOGEXVJDWHZD\V

www.wago.us/pfccloud
 REMOTE TRAINING
Implementing remote
technical training
By using an Industrial Internet of Things (IIoT) gateway, or a remotely controlled PC,
critical how-to skill-based training can be made available to engineering students
anywhere there’s an internet connection.
By Matt Pelletier
Ya s k a w a A m e r i c a I n c .
T
oday it is possible to provide your customer
with remote technical training, including hands-
on time with your product. Industrial devices
such as programmable logic controllers (PLCs)
and servos rely on an Ethernet or universal
serial bus (USB) connection for troubleshooting,
configuration, and programming. This traditionally means
that you have to be close to the device to learn how to
use it. But by using an Internet of Things (IoT) gateway,
or a remotely controlled PC, critical how-to skill-based
training can be made available to students anywhere
there’s an Internet connection (see Figure 1). This also
means that students can follow along with tutorial videos
to learn at their own pace, on their own PC, just like they
would with software-only eLearning.
How it works
Consider a customer who requires hands-on training
to become comfortable with the programming and con-
figuration of a PLC. Traditionally, either the customer
must travel to your office, or you and the devices must
travel to the customer. Naturally there is a cost in both
A10 • June 2018 Applied Automation
time and money to make this happen. Enter the IIoT
gateway. This connects the customer PC to the devices.
Think of it as a really long cable going from the custom-
er’s PC all the way to the devices in your office. Add an
IP webcam and the customer can see how the device
responds.
Industrial IoT (IIoT) gateways and virtual private net-
works (VPNs) have been used for years to allow remote
diagnostics and troubleshooting of computer systems
and industrial automation systems. In the past, these
systems could be complicated to manage, only worked
within specific networks, or posed a security risk. In
short, they often did not work. But today it is possible to
get stand-alone units that operate independently over a
4G wireless connection to the internet, making operation
simple and keeping the IT department happy. This same
technology can be leveraged to make remote hands-on
training possible for any Ethernet or USB device.
Whose PC is best?
Why go through the IIoT gateway? Why not simply let
the student remotely control a dedicated training PC?
(See Figure 2.)
There are pros and cons to each method. One consid-
eration is software installation. Ultimately, if the students
are your customers (or potential customers), they will
have to install your soft-
ware on their computers.
Any installation problems
can be solved on a case-
by-case basis, without
wasting classroom time
as you would in a live
class. When students
Figure 1: An Industrial Internet
of Things (IIoT) gateway as
part of a remote training
solution. All images courtesy:
Yaskawa America Inc.
install and use the soft-
ware on their own PC,
this creates a sense of
confidence, familiarity,
ownership, and buy-in to
the product as a whole.
The projects created in
training are right there on
their PC. It is a small step
from the remote training
equipment to your own
device when the computer
software is working. When
everything is working on
the student PC, uncer-
tainty about the setup of
the training PC is elimi- Figure 2: A remotely controlled PC as
nated. Another benefit to part of a remote training solution.
remote connection is that
students can log back in
to test their own programs, once again, using their own aspect of the device’s online configuration. The students
computers. This remote system can take some of the can follow along (on another monitor), complete prac-
load off the sales demos units. tice exercises, and share their screen to receive help
Software installation often is not a problem, but and immediate feedback. Teaching a group of students
sometimes it can be due to software licensing and PC remotely does require a bit of finesse in order for the
configuration lockdown by the IT department. If this instructor to efficiently manage every interaction through
is the case, or if your software is prone to a cumber- the computer screen. But it is easy to justify the incon-
some or lengthy installation process, then it may be venience of the interface with the convenience, savings,
best to provide a PC all ready to go. Students can log and flexibility afforded by avoiding travel.
into a PC, control it remotely, Another option for live training
and proceed with the training. is to leave the equipment con-
In this setup, you may still find Prerecorded self-guided nected to the IIoT gateway back
benefit to using an IIoT gateway in the office, and the instructor
or use the simpler solution of training requires the most alone travels to the students.
remote PC software. Keep in Then conduct the training as
mind, however, that you lose the work up front, but it can reach you normally would if the equip-
aforementioned benefits. Skills ment had been shipped to the
developed by the students while a large number of trainees. training site. There are a few
using the training PC will soon differences, however. First, you
diminish unless they can install the software and make don’t have to ship equipment, which means no dam-
the connections on their own devices. Also, the remote age and no delays. Also, your only view of the device is
PC may have a lag in response time. Video quality from through a webcam, which is useful, but not usually near-
the webcam also may suffer. This is still a good option, ly as satisfying to the trainees as having the device right
however. Consider providing a PC as a backup even if in front of them. This option is best suited for situations
the student’s own PC is the first choice. where the device is large or otherwise immovable, and
for international training where shipping your product to
Live and self-guided training the training site in another country is likely to result in
There are two basic methods to deliver training with customs delays out and back.
remote hands-on access to your devices: live training, Prerecorded self-guided training requires the most
and prerecorded self-guided training. work up front, but it can reach a large number of train-
For live training, the most travel-efficient option is to ees. With this method, the instructor presents the
start up a screen-sharing session with the trainees—a training material, instructions, and demonstrations in a
webinar of sorts. The instructor can present training produced video. The student follows along and can go
material, give instructions, and demonstrate a certain online with their remote connected equipment to try it

Applied Automation June 2018 • A11

 R e m o t e tR a i n i n g

for themselves. While this method It is helpful to run the class test answer if the trainee truly
does not have the advantage completes the required task. This
of instructor interaction, there could be fixing a program error,
are other advantages. If a topic
live a few times and make finding or setting certain data, or
was unclear, or the student was generating and clearing a specific
distracted, all they have to do is adjustments. Then you alarm code. The “hidden code”
rewind the video. They can adjust could detect the existence and
the video playback speed to use know the types of questions disappearance of the alarm. While
their time more effectively. In other this type of test can be difficult to
words, the student can learn at people have, and the typical create, in many ways it is superior
a comfortable pace and at any to direct instructor observation, as
time. A new-hire can immediately places they get stuck. it raises the bar for all trainees to
take the courses in the optimum the same level. Some may need
sequence without delay. No more more time to get to that level,
waiting for an opening in the next training session, hoping some may not. But it’s an absolute level and all certified
it fits your schedule. Plus, later when the details become a trainees will have achieved that level. Additionally, this
little foggy, the video is still there for reference. type of test provides motivation to the student (engineers)
It is helpful to run the class live a few times and make and provides a satisfying sense of accomplishment when
adjustments. Then you know the types of questions people the answers appears. When these students show up for
have, and the typical places they get stuck. As an instruc- more advanced training, those who passed such a test
tor, you can then anticipate these questions and pitfalls, will be at about the same level.
addressing them directly in the video recording.
Looking ahead
Testing, certification, and evaluation So, is it possible to provide your customer with remote
How can you tell if the student actually acquired the technical training, including hands-on time with your prod-
skills necessary to use your device? If it were a live uct? The answer is “yes,” you can provide training to con-
class, the instructor can observe the student and ensure nected industrial devices remotely. It can be done in the
a level of participation. But for self-guided training, you same ways that software-only training has been done over
can’t even tell if the student was truly watching the vid- the Internet for years. You just need an IIoT gateway, or
eos. Did they really do the exercises? a remotely-controlled training PC. Set up a sales demo of
Naturally, there is the multiple-choice test to get some your product with a webcam pointed at it and hold a short
clue. But remember, the student has access to your prod- basic web training session with an example application to
uct during the test, and you’re not limited by an absolute solve (see Figure 3). Let the students use the equipment
“class over” deadline. This makes way for more creative remotely. When you’re comfortable delivering this training,
problem-solving types of test questions that would not produce a video of it and let people do the training at their
even be practical in a live class setting. For example, in own schedule. Build from there and you’ll eventually have
a programmable device such as a PLC, it is often pos- a library of video training tutorials and complete hands-on
sible to “hide code” in the program that only gives the training courses that give your customers how-to training
with the substance and skills required to connect to and
configure your product successfully.

Matt Pelletier is a product training engineer at Yaskawa

America Inc., where he has worked since 1999. He has
worked extensively with product engineering to develop
interactive hands-on training for servo tuning, IEC 61131,
PLCopen, and advanced programming workshops for
rotary knife, PackML, robots, and conveyor tracking. He
also has created a library of training videos with hands-
on access to remote servo and controller equipment,
which are available free of charge on Yaskawa’s website.
Otherwise known as “Matt Servo,” he is a specialist in the
application of Yaskawa servos and motion controllers in a
variety of industries, authoring several articles in various
publications. Pelletier has an electrical engineering degree
from the University of Wisconsin, Madison.
Figure 3: Yaskawa’s remote training demo cart.

A12 • June 2018 Applied Automation

 A DV E R T I S E M E N T

AutomationDirect
We ship super-fast (and FREE on
orders over $49). The majority of our
products are stocked for same-day
shipping, when you place your order
by 6p.m. E.T. (with approved company
credit or credit card). Plus, you get
free two day (transit) shipping on
orders over $49 within the U.S.,
Canada and Puerto Rico; shipped via
ground service or LTL (certain heavy
items are excluded). We guarantee it.

We want you to be pleased with

every order. That’s why we offer a
30-day money-back guarantee on
Company headquarters located just north of Atlanta, Georgia
almost every stock product we sell,
including our software (see Terms and
A well-recognized name in the industrial automation Conditions for certain exclusions).
market, AutomationDirect is a distributor of thousands
of products including Programmable Logic Controllers
(PLCs), AC/DC drives and motors, operator interface
panel/HMIs, power supplies, sensors, pushbuttons,
NEMA enclosures, pneumatic supplies, wire, and
much more. In business since 1994, the company
headquarters is located just north of Atlanta, Georgia.

For over 20 years we’ve been saving our customers

time and money on industrial automation products.
We have a huge inventory that is constantly growing
in order to provide you with the quality components
needed to keep your projects on schedule. We’ve heavily Orders ship quickly from our state-of-the-art warehouse
invested in new infrastructure that will allow us to
continue offering the service and support you deserve.

We make ordering easy and our service For more information,

is exceptional. Shop online with our contact us at 800-633-0405
exhaustive product listings or browse or visit us online at
our online catalog; fax or phone us – www.automationdirect.com.
you’ll get friendly, efficient service
from the most helpful sales team in the
business. Independent surveys completed
by readers of industrial trade magazines
for their Readers’ Choice Awards have placed
us at the top of the list for service 15+ years in a row.

1-800-633-0405 | AutomationDirect.com
 A DV E R T I S E M E N T

New Drive and Maintenance Management Solutions

from SEW-EURODRIVE
CDM® Maintenance Management
SEW-EURODRIVE now offers a full complement of drive maintenance
services. Our CDM® Maintenance Management service provides
an online portal and complete overview of your entire stock of drive
components, condition of your units, drive usage, and service details.
With 24/7 online access, CDM removes the headache of managing
your maintenance and inventory.

Pick-Up Box Service

Let SEW-EURODRIVE be a part of your maintenance team to
free up your crew for other tasks. This new service provides a
dedicated on-site Pick-Up Box, along with scheduled pick-up,
repair, and return of your drive units. Each unit is examined by an
experienced SEW-EURODRIVE service technician. Service or repairs
are completed after approval.

MOVIGEAR®
The MOVIGEAR® Mechatronic Drive System for horizontal
materials handling from SEW-EURODRIVE sets new standards in
terms of efficiency and functionality. MOVIGEAR® combines the
gear unit, motor and electronics within one highly reliable, efficient,
and hygienically designed unit. Not only does independent research
prove that MOVIGEAR reduces total start-up cost and annual
operating expenses by 20-30%, but actual installations have seen
even higher savings…by as much as 50%!

DRC Electronic Motor

The DRC electronic motor provides an ultra-efficient motor and
electronics package for those SEW gear units already installed in
your system. Like MOVIGEAR, the DRC electronic motor consists of a
permanent-field synchronous motor with integrated drive electronics
in a completely enclosed housing. Step up to IE4 efficiency — the
next level beyond premium.

About SEW-EURODRIVE
Engineering excellence and customer responsiveness distinguish
SEW-EURODRIVE, a leading manufacturer of integrated power
transmission and motion control systems. SEW-EURODRIVE solutions
set the global standard for high performance and rugged reliability
in the toughest operating conditions. With its global headquarters in
Germany, the privately held company currently employs over 16,000
employees with a presence in 48 countries worldwide. U.S. opera-
tions include a state-of-the-art manufacturing center, five regional assembly plants, more than
63 technical sales offices and hundreds of distributors and support specialists. This enables
SEW-EURODRIVE to provide local manufacturing, service and
support, coast-to-coast andaround the world.

P: 864-439-7537 | F: 864-439-7830 | www.seweurodrive.com

 Less is more.
Too much inventory? We can help! The
MOVIGEAR® Mechatronic Drive System from
SEW-EURODRIVE substantially reduces your
inventory with its ability to cover a broad range

of gear ratios with a single unit. Independent

research has also proven that the MOVIGEAR®
reduces start-up and operating costs in material
handling by 20-30%. So, relax...we got this!

movigear.com / 864-439-7537
Less means more!

Focused on the essentials: the new i500

Slim design, scalable functionality, and extremely user-friendly.
The groundbreaking i500 is size-optimized and allows for zero-
clearance mounting, saving valuable cabinet space. And thanks
to the innovative interface options, it’s easy to commission in
minimal time. The best thing of all is that the modular structure
adapts to different production configurations in no time at all.
Less does mean more!
To learn more, visit www.Lenze.com. As easy as that.