Office-grade versus Industrial-grade
Computer Comparison
Sarah Poehnelt and Matthew Hansen, Rockwell Automation
You need a computer for an industrial environment. What
factors should you consider before you make an investment
in a computer?
Allen-Bradley Integrated Display Industrial Computers
Computer technology at competitive prices has allowed office-grade
computers to dominate the computer market, leading them to be used in
many different environments. However, most computer buyers do not consider
how office-grade computers are not built for industrial environments—they
are built to operate in relatively clean, climate controlled environments
What is an Industrial Environment?
An industrial environment would include any of the following factors:
• Extreme temperatures or wide temperature fluctuations
• Humidity
• Vibration
• Shock
• Airborne particles (such as dust and smoke)
• Corrosive materials
• Power quality (unreliable or fluctuating power sources)
• Magnetic fields or other emissions
• Rough operator interfaces (dirty hands or gloves on keyboards)
• Wash-down requirements
• Hazardous location requirements (for example, where explosive gases may be present)
Any of these industrial environment factors can affect office-grade computer performance and reliability, and eventually
contribute to a shortened life.
2 | Office-grade Computer versus Industrial-grade Computer Comparison
Why an Allen-Bradley Industrial-grade Computer?
Allen-Bradley selects the highest quality parts and designs their products to withstand
the realities of industrial environments. Consider the three primary factors that distinguish
Allen-Bradley industrial-grade computers from office-grade computers.
Factor 1: Components
Manufacturers of office-grade equipment typically select components with cost as
their primary criterion. Component quality and reliability are important but they are not
selected or tested to withstand prolonged exposure to an industrial environment.
Components in Allen-Bradley computer equipment are selected specifically to withstand
industrial environments:
• Shock-mounted hard disk drives or solid state drives
• Secure connected circuit boards for critical components
• Gold-plated connections
• Physical/locking restraints on connectors
• Tie-downs to secure components and peripherals
• Cables routed and tied down to ensure minimal interference
• Corrosive-resistant metal for the chassis
Example: Many of Allen-Bradley computer models can be ordered with solid-state drives
(SSDs), which are more durable than rotating hard disk drive (HDD) media. To further
enhance durability, Allen-Bradley uses single-level cell (SLC) memory instead of multi-level
cell (MLC) memory on SSDs. SSDs also provide longer durability versus HDDs for enhanced
operation during rigorous industrial shock and vibration.
Table 1 - SLC and MLC Memory Advantages
Most office-grade solid-state
drives use multi-level cell (MLC)
memory to reduce costs but at
the expense of drive durability.
Drive Media Factor
SLC
MLC
High density
√
Low cost per bit
√
Endurance
√
Operating temperature range
√
Low power consumption
√
Write/erase speeds
√
Write/erase endurance
√
These component guidelines allow Allen-Bradley products to operate at the maximum
specifications, it also means that these higher-grade components last longer in an
industrial environment. Allen-Bradley selects components based on durability and
performance in their products.
Office-grade Computer versus Industrial-grade Computer Comparison | 3
Factor 2: Design
Even a computer with the highest-quality components won’t thrive in an industrial
environment unless it has been designed with specific factors in mind.
Allen-Bradley computers are designed with:
• Resistance to mechanical shock and vibration (hard drives are shock-mounted, components are placed in the most stable locations)
• Resistance to higher temperatures (through effective thermal design and placement of
heat sinks)
• Higher corrosion resistance on critical components
• Integrated components to eliminate exposing critical components to environmental
hazards
• Robust mounting systems (wall/panel/rack/machine mounting)
• Low maintenance (fanless design)
Compact Non-Display Industrial Computer
• Consistent component availability, selecting long-life parts to ensure availability
An important design element for Allen-Bradley industrial computer products is component
derating, which is selecting components that exceed required specifications. Allen-Bradley
uses component derating for higher quality levels and product longevity.
Example: If a component’s maximum operating temperature is 85 °C (185 °F), then
component life doubles for every 10 °C (50 °F) cooler that the actual environment is
(theoretic average).
Table 2 - Design Comparisons
Allen-Bradley
Industrial-grade
Computer
Variable
Mounting applications
Typical
Office-grade
Computer
• Table
• Table
• Desktop
• Desktop
• Wall
• Panel
• Rack
• Machine
• DIN rail
Chassis design
Cast aluminum or
stamped steel
Thin, formed
sheet metal
Shock mounted drives
Yes
No
Shock rating, max
30 g (1/2 sine, 11 ms)
Typically not rated
Vibration rating, max
2 g @ 10 to 640 Hz
Typically not rated
Operating temp. range, max
-20 to 70 °C (-4 to 158 °F)
10 to 35 °C (50 to 95 °F)
4 | Office-grade Computer versus Industrial-grade Computer Comparison
Factor 3: Testing and Certification
Office-grade computers are tested and certified for office environments but not for
industrial environments. Allen-Bradley fully tests their computer equipment for all
conditions found in an industrial work environment. Allen-Bradley goes beyond officegrade certifications by achieving industrial certifications, including those for harsh
environments.
Table 3 - Testing and Certifications for Allen-Bradley Computers
Non-Display Industrial Computer
Testing Criteria
Certifications
• Shock (operating
and non-operating)
• Thermal
• Safety
UL Mark
• Vibration (operating
and non-operating)
• Wattage
• Agency
CE Mark
• Performance and
benchmark
• Power cycle
• EMC
C-Tick Mark
• Extended reliability
• Hose-down/IP
• HALT
ATEX Mark
• Operating system
validation
• Functional
• BIOS/UEFI
Country specific marks
(such as Korea & China)
• Signal integrity
Testing Computers Against Common Industrial Conditions
To better understand the effects of an industrial environment on office-grade computers,
Allen-Bradley selected several office-grade computers with hard disk drives (HDDs). Along
with Allen-Bradley computers, these computers were put through common industrial
conditions such as shock, vibration, and thermal tests.
Table 4 - Tested Computers
(1)
Computer
OS
Intel Processor/
Speed (GHz)
RAM Type/
Installed (GB)
HDD Qty./
GB (each)
Allen-Bradley 1
XP Pro
Core™2 Duo/1.66
DDR2/4
2/160
Allen-Bradley 2
XP Pro
Pentium™4/3
DDR2/2
2/160
Office 1
XP Pro
Core™2 Duo E7300/2.66
DDR2/2
1/160
Office 2
2008 R2(1)
Xeon® E5506/2.13
DDR2/4
1/250
Office 3
7 (32 bit)
Celeron® Dual E3300/2.5
DDR3/3
1/160
Office 4
XP Pro
Xeon® Dual W3505/2.53
DDR3/3
1/320
Office 5
7 (32 bit)
Core™ i5-650/3.2
DDR3/2
1/160
Windows Server 2008 R2
Office-grade Computer versus Industrial-grade Computer Comparison | 5
Test 1: Vibration
Vibration testing was chosen because computers in industrial environments are typically
placed near motors or machinery. Figure 1 and Table 5 show vibration test results.
Figure 1 - Vibration Test Results (10 to 640 Hz range)
Breakdown of 26%:
13%: BSOD*
12%: Complete failure
1%: Hard start required
Functionality Percentage
100
80
26%
60
50%
Inconsistent
Operation
40
14%
10%
20
0
Stopped
Operating
Fully
Operational
Slowed Operation
AllenAllen
Bradley
Office
1
Office
O
2
O
Office
3
Office
O
4
Office
O
5
Office-Grade Performance Breakdown
* BSOD = Blue screen of death
Vibration test results showed office-grade computers struggled with typical industrial
environments:
• Over 85% of the office-grade computers failed to remain fully operational
• 60% of office-grade computers displayed inconsistent or slowed operation
• Over 25% of the office-grade computers stopped operating
Part of the vibration test simulated different frequency ranges. Allen-Bradley also tested for
slightly dampened (when computers are mounted) and amplified frequency ranges (when
computers are placed near or next to system motors).
The frequency performance results were based on the following scale: Acceptable (100% to
50% processing); Unacceptable (50% to 15% processing), and Failed (less than 15%).
Table 5 - Frequency Performance Results (10 to 240 Hz range)
Computer
Typical Motor
Frequency
(50/60 Hz)
Dampened Motor
Transfer
(10 Hz)
Amplified Motor
Transfer
(120 Hz)
Office 1
Unacceptable
Acceptable
Unacceptable
Office 2
Unacceptable
Acceptable
Unacceptable
Office 3
Failed
Failed
Failed
Office 4
Unacceptable
Acceptable
Unacceptable
Office 5
Failed
Failed
Failed
Allen-Bradley
Acceptable
Acceptable
Acceptable
Operational faults such as BSOD, manual restarts, and complete failure can lead to
significant data corruption and lost production time. Irreplaceable damage can cause
significant down time and may require reinstalling software programs and drivers.
6 | Office-grade Computer versus Industrial-grade Computer Comparison
Test 2: Shock
Industrial shock environments include hydraulic machine presses. Machine presses exert
massive amounts of energy over short intervals of time, which create large shock forces.
Therefore, computers used in this industrial environment must withstand the pressure and
energy force that is dispersed.
Based on the shock test results, 60% of
the office-grade computers exhibited
significant movement in interior
components to fail the test. In some
cases, the component movement simulated
accelerations near 70 g.
Table 6 - Shock Testing Results
Computer
Hydraulic Machine
Press
(15 g shock)
Office 1
Failed
Additionally, the office-grade computers saw
Office 2
Passed
significant abrasion problems, a combination
Office 3
Failed
of shock and
limited mounting
Office 4
Passed
(securing) options.
Most office-grade
Office 5
Failed
Most office-grade computers
computers do not
do not offer mounting
Allen-Bradley
Passed
offer mounting
features as part of
features as part of their
their design, which
design, which is critical to
is critical to counter shock deterioration. Therefore, attempts to
secure office-grade computers for shock often result in insecure
counter shock deterioration.
and improper mounting. The subsequent enclosure damage
and component failures will cause serious troubles in industrial
settings, such as constant repair and downtime.
Allen-Bradley designs proper mounting methods for the greatest strength and stability.
Shock-mounted drives and other components are built to withstand shock environments.
Being equipped with Allen-Bradley industrial-grade computers provides the peace of mind
needed for running an industrial company.
All Allen-Bradley industrial computers offer mounting that
can withstand the challenges of industrial environments.
Office-grade Computer versus Industrial-grade Computer Comparison | 7
Test 3: Operating Temperature
Allen-Bradley products are also designed and tested for intense temperature environments
(up to 70 °C or 158 °F) for which office computers are not. These environments include
heating/refrigerated food processing, glass and aluminum process, and cement furnaces.
Office-grade products encounter significant problems when placed in extreme operating
temperature environments.
Temperature locations evaluated during this testing included:
• External
• Power supply coil
• Memory
• Upper case
• Northbridge
• Optical drive
• Lower case
• Hard drive
• Heat sink
• Post CPU
• Processor cores
• Motherboard
• Power supply
• CPU
Based on the test results, 78% of the office-grade
computers were within 5 °C (41 °F) or outside their
rated temperature range. Only 22% of the internal
components for these computers were properly
cooled in the tested temperature. Component
overheating leads to rapid deterioration, which affects
computer performance, reliability, and longevity.
22%
Within
Manufacturing
Specifications
78%
Outside
Manufacturing
Specifications
Whereas office-grade computers experienced
difficulties maintaining proper component cooling in
an industrial environment,
Allen-Bradley performed well
in all environments. Allen-Bradley’s
Allen-Bradley’s focus on
focus on system reliability and operational performance provides
confidence in your system for all industrial environments.
system reliability and
operational performance
provides confidence . . . for all
industrial environments.
8 | Office-grade Computer versus Industrial-grade Computer Comparison
Industrial Design Benefits
Even with higher specifications and sturdier construction, many are deterred from
purchasing an industrial-grade computer because of its initial cost when compared to an
office-grade computer.
Industrial-grade components are more expensive because they are rated and designed to
handle harsh environments. Components such as RAM, hard disk drives, solid-state drives,
optical drives, LCD displays, touchscreens, and motherboards require increased ratings to
operate reliably in industrial environments.
An industrial rated product is
the better return . . . because of
its lower total cost over product
life and how it consistently keeps
processes up and running.
Other key components such as processors are chosen from
imbedded roadmaps to increase long term availability and
support.
Lower Total Cost of Ownership
Some businesses use office-grade computers in industrial
settings until they fail, viewing them as “disposable” commodities
that can be quickly replaced.
While the initial cost of purchasing office-grade computer
systems may be lower, consider the following factors that lead to
costly consequences.
Higher Costs:
Lower Productivity:
• Unplanned downtime and lost production
• Higher repair cycle turnaround
• Continual replacement
• Replacement requires downtime
• Higher maintenance and IT costs
• Computer unreliability reduces
process time and efficiency
• Additional costs for enclosure cooling
and mounting
• Failures can corrupt or lose critical data
• Complex and time consuming
mounting solutions to overcome
non-standard enclosure dimensions
An industrial rated product is the better return on investment because of its lower total
cost over product life and how it consistently keeps processes up and running.
The costs associated with replacing failed office-grade computers is especially high when
you factor in unplanned downtime and lost production.
Office-grade Computer versus Industrial-grade Computer Comparison | 9
Technical Support
The promise of 24-hour technical support from an office-grade computer manufacturer
may seem like a benefit. However, Allen-Bradley offers 24-hour support by personnel
trained to work with industrial customers.
Troubleshooting a problem in an industrial environment presents unique challenges that
are beyond the scope of training and experience of typical technical support personnel.
Allen-Bradley has extensive experience with troubleshooting in industrial environments
including industrial networks, grounding/current loops issues, and heat dissipation/panel
design. Allen-Bradley offers support not only with industrial computers, but also software/
application, network, and other parts of the control system.
Allen-Bradley focuses on the stability of operational platforms so your system is rugged
enough to handle industrial settings. Allen-Bradley offers longevity of support with rapid
repair turnaround and maintenance to their products. Allen-Bradley also provides support
as needed for computer migrations between series.
Allen-Bradley offers global service and support. With a worldwide network of personnel
that are experienced in the needs of industrial customers and environments, Allen-Bradley
products give the peace of mind that technical support is always available.
Visit the Rockwell Automation Support site for more information.
Allen-Bradley, LISTEN. THINK. SOLVE. and Rockwell Software are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 6000-WP001B-EN-P – June 2013
Supersedes Publication 6000-WP001A-US-P – June 2000
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in the U.S.A.