PERCEPTION
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REALITY
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RELIABILITY
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PLCs are more reliable than DDCs, and I can’t afford any controller downtime.
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Both controller types are reliable options; however, the choice depends chiefly on the use application. DDCs are ideal for environments like data center office spaces, whereas PLCs may be more reliable within critical infrastructure areas that demand higher durability and environmental resilience such as chiller systems. Additionally, the service and support provided by the controller manufacturer may be important factors in reaching a controller design decision.
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REDUNDANCY
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I need a redundant controller for every piece of critical equipment.
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Redundant control can be crucial for maintaining uptime in critical data center applications. Working with an application engineer, it is possible to create a controller architecture that provides a scalable, layered approach to redundancy. An ideal system design will provide a cost-effective approach tailored for application criticality.
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PERFORMANCE
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I need the fastest controller.
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Some applications like an EPMS (Electrical Power Monitoring System) in a data center require millisecond data granularity and control. Many other applications like HVAC don’t require the same level of performance. This highlights the need for a tailored, application-driven design that uses the best available technology for the respective task.
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EASE OF PROGRAMMING
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PLCs are too complicated for data center applications.
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DDCs typically offer simplified programming with pre-built application blocks, making them well suited for basic control tasks. PLCs often offer more flexibility and scalability with standardized programming, modular libraries, code reuse and open integration to enable consistent engineering across diverse applications. Using an open integration framework can help reduce complexity by managing data from all devices thus minimizing the need for multiple, disparate tools across a data center.
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UNIVERSALITY
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A controller used in manufacturing is fine for critical infrastructure.
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Data centers require ultra-high reliability, with tolerance for power interruptions, temperature fluctuations and cyber threats. Many general-purpose PLCs typically used in manufacturing environments may lack advanced networking, redundancy and data integration features critical to data center monitoring (e.g., integration with BMS, SCADA or DCIM platforms).
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CYBERSECURITY
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Cybersecurity is not yet a major concern for controllers.
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Industrial controllers are increasingly connected to operational technology (OT) networks and cloud systems, which makes them potential targets for cyberattacks. Many older controllers lack built-in security features like encrypted communications, role-based access control or secure boot. It is important to consider product cybersecurity when selecting controllers looking for solutions built with privacy and security by design. It’s also critical to build in cybersecurity controls, protocols and tools into the control system architecture to help prevent remote tampering, malware or data breaches.
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SPEED AND PERFORMANCE
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Faster processors mean better performance.
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Performance in data center environments is more about reliable deterministic behavior, real-time control and system integration than raw speed. Over-specifying can lead to wasted budgets without improving system robustness, while underestimating input/output (I/O) latency or cycle times can cause thermal, electrical or cooling system instability.
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IT AND OT REQUIREMENTS
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Controllers can be managed with the same practices and expectations as IT systems.
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OT systems often require higher reliability, real-time processing and different security considerations than IT systems. It is imperative to involve experienced controls engineers in the architecture phase of system design.
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SERVICE
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Working with multiple vendors for your data center infrastructure is a smart approach.
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Managing data centers is complex. Working with a single, trusted partner can streamline deployment and simplify integration. When the installed systems are serviced and supported by one partner, you can improve accountability and response times, allowing your team to focus on uptime and operational efficiency.
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TOTAL COST OF OWNERSHIP
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PLCs are far more expensive than DDCs.
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While there are applications in which the requirements dictate a more expensive PLC-based solution, this is not always the case. Cost-effective PLC solutions are available to meet the demands of high availability, mission-critical environments. Depending on the specific application requirements, a range of competitive solutions – spanning both DDCs and PLCs – can be tailored to support diverse operational needs.
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