freewave i/o for rockwell curt goldman market manager, utilities randy maesrockwell specialist bret...
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FreeWave I/O for RockwellFreeWave I/O for RockwellCurt Goldman Market Manager, Utilities
Randy Maes Rockwell Specialist
Bret Dianich Western Region BDE
Nichole Pettway Eastern Region BDE
February 27, 2012
Application examples
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1. Technology Overview
2. FreeWave I/O Products: I/O Expansion
3. Applications for FreeWave I/O and Rockwell
4. Compatibility Between Allen-Bradley PLC’s and FreeWave I/O
FreeWave I/O for RockwellAgenda
FreeWave I/O for Rockwell:Technology Overview
FreeWave I/O for Rockwell:Technology Overview
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What is Wireless I/O?
• Replaces wires with wireless radio frequency technology to measure sensor outputs and control process elements using digital and analog signals
• FreeWave has the industry’s best radios for frequency-hopping spread spectrum radios for unlicensed frequencies and reliable licensed frequencies with distances over 60 miles
FreeWave I/O for RockwellTechnology Overview
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What are the benefits of Wireless I/O?
• Wireless I/O saves time and money in engineering, material, installation, commissioning, logistics, maintenance, diagnostics, permitting and equipment lifetime.
• Wireless I/O is available for use with free or licensed radio frequencies and implies protection by the FCC
• Wireless I/O provides security, reliability and ease of use to automated measurement and control systems
FreeWave I/O for RockwellTechnology Overview
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What do we measure?
• Sensor output for pressure, level, flow, temperature, chemicals, etc.
• Raw inputs for emergency stop, battery voltage, temperature, etc.
What do we control?
• Relays, valves, latches, pumps, alarms, actuators, etc.
FreeWave I/O for RockwellTechnology Overview
FreeWave I/O for RockwellFreeWave I/O for Rockwell
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I/O Expansion
• Modular, expandable I/O for wireless and wired applications
• Up to 192 I/O points at a single location without adding more radios
• Add I/O to any PLC, RTU or serial Modbus device
Wireless I/O for Rockwell
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Key Features of I/O Expansion
• Maximum analog input reading error of 0.10% across entire temperature range
• 12 I/O channels per module
• Supports 4 to 20 mA, 1 to 5 V and 0 to 10 V sensors
• Non-isolated digital outputs drive 1 A and isolated relay digital outputs drive 2 A
• Integrated DIN-rail mounting clip
• Operational temperature range from -40 to 75 °C
Wireless I/O for Rockwell
Wired I/O Expansion
Wireless I/O for Rockwell
Wireless I/O Expansion
Wireless I/O for Rockwell
FreeWave I/O for Rockwell:Applications
Electric PowerWater Purification
Wastewater Treatment
FreeWave I/O for Rockwell:Applications
Electric PowerWater Purification
Wastewater Treatment
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Typical Applications in Electric Power:
• Circuit breaker monitoring
• Transformer condition monitoring
• Switch monitoring
FreeWave I/O for RockwellApplications
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Typical Applications with Water:
• Pump control *
• Water tower monitoring *
• Irrigation
FreeWave I/O for RockwellApplications
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Typical Applications with Wastewater:
• Lift Stations *
• Water quality monitoring
• Chemical pumps
FreeWave I/O for RockwellApplications
FreeWave I/O for RockwellApplications
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Pump Control
• Keep water tanks at purification plant input full during peak usage times
• Reservoirs and water tanks can be separated by many miles
• Manual pump operations are costly and inefficient
FreeWave I/O for RockwellApplications
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Pump Control with Wireless I/O
• In the main control room:
• Serial radio, Programmable Logic Controller (SLC), Human Machine Interface
• In the pump house:
• Serial I/O radio, variable frequency drive (PowerFlex), pressure transmitter, flow meter
• At the water tank:
• Serial I/O radio, level meter, pressure, flow meter
FreeWave I/O for RockwellApplications
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Benefits of Pump Control with Wireless I/O
• Monitor tank level to ensure supply during peak demand
• Monitor line pressure throughout the pipeline
• Control the variable frequency drive based on the reported flow rate when the pump is running
• Adds reliability with real-time measurements and controls wirelessly
• Reliable, flexible, cost-effective and scalable system for long-range systems
FreeWave I/O for RockwellApplications
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Water Tower Monitoring
• Pressure must be monitored for water towers providing distribution line pressure
• Water level must be monitored for water towers providing storage
• Manual reporting of water tower level and pressure can be hazardous and unreliable
FreeWave I/O for RockwellApplications
FreeWave I/O for RockwellApplications
Compatibility
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Benefits of Water Tower Monitoring with Wireless I/O:
• Allows real-time reporting of water tower level, water tower temperature and line pressure
• Provides alarm capabilities from the water tower
• Increases employee efficiency
• Extends the range of the wireless SCADA network
FreeWave I/O for RockwellApplications
FGR2-IO, Modbus RTU and Allen-Bradley PLC’S
Compatibility
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Lift Stations
• Lift stations fill collection locations at the input of the wastewater treatment process
• Manual monitoring of sewage lift stations can easily result in overflows
• Wells with sewage stored over a long time can succumb to septic leakage
FreeWave I/O for RockwellApplications
PLC overview
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Benefits of Lift Station with Wireless I/O
• Automatic alarm capabilities notifies of overflow risk
• Continuous reporting of well level communicates excessive storage times of sewage and indicates septic risk
• Increases employee efficiency
FreeWave I/O for RockwellApplications
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• Micro 800 Family• Micro 830
• Micro 850 (when released)
FGR2-IO, Allen-Bradley compatibility
• MicroLogix• 1100
• 1200
• 1400
• 1500
• SLC
• 5/03
• 5/04
• 5/05
• CompactLogix• 1769-L23
• 1769-L23E
• 1769-L31
• 1769-L32E
• 1769-L32C
• 1769-L35E
• 1769-L35E
• 1769-L35CR
• 1769-L43
• 1769-L45
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Micro800 family
PLC overview
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• Micro 830/850• Embedded communications port as well as USB
programming port
• Communications port is Modbus RTU Master and ASCII only (no Modbus RTU Slave or DF1)
• Ladder logic uses function blocks with tags
• All message instruction programming is done via tags
PLC overview
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MicroLogix family
PLC overview
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• MicroLogix 1100, 1200, 1400 & 1500• All four have a channel 0 port that is capable of Modbus
RTU Master or Slave
• The MicroLogix 1400 and 1500LRP have two serial ports capable of Modbus RTU Master or Slave
• When using a channel 0 port Allen-Bradley’s PMO2 cable is required for connectivity
• All needed communications programming is done in the message instruction
• The channel 0 port must be configured as a Modbus RTU Master before a message instruction can be correctly configured
PLC overview
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SLC500 family
PLC overview
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• SLC5/03,4 & 5• Firmware 10 or later needed for Modbus RTU
functionality• In SLC5/03 & 4 the firmware is upgraded by replacing a
processor chip
• In SLC5/05 the firmware is upgraded via ControlFlash software
• There is no Modbus RTU Slave functionality
• The channel 0 port must be configured as a Modbus RTU Master before a message instruction can be correctly configured
PLC overview
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CompactLogix family
PLC overview
Application examples
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• CompactLogix with 1769-SM2 module• Provides three serial ports
• All three ports can be configured as a Modbus RTU Master
• No Modbus RTU Slave
• All three ports are RS-485 only
• Message instructions are “Generic CIP” type instructions
• All communication configuration parameters are configured via tags including port settings (baud rate, timing, etc…)
PLC overview
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• CompactLogix with MicroLogix 1100/1400• MicroLogix communications run independently
• The MicroLogix and CompactLogix don’t have to be co-located (networked via EtherNet/IP)
PLC overview
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• Micro830 wired I/O expansion
Application examples
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• MicroLogix 1500LSP with wireless I/O
Application examples
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• SLC5/05 with multi-drop wireless I/O
Application examples
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• CompactLogix w/ 1769-SM2
Application examples
Questions?
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• CompactLogix w/ MicroLogix as Modbus RTU Master
Application examples
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• CompactLogix w/ MicroLogix as Modbus RTU Master
Application examples