The field wiring for our customer became very complex because they wanted verification that each of the twenty actuated valves is in the correct position. Also, the system is pre-programmed to allow up to four additional greensand filter units through a HMI touchscreen. If the control panel with the Allen Bradley PLC is only 10 feet from the first tank, fully outfitted, this control architecture would save over 2.8 MILES of wire, 1600 electrical terminations and 80 pneumatic connections and countless hours of wiring and troubleshooting!
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| Fieldbus Distributed I/O Module Blocks Installed n Each Greensand Filter Unit |
- Requires only two cables (Ethernet and low voltage Power) from each block to the main control panel eliminating point-to-point wiring from each system to main control panel
- Eliminates over 840 sources of potential errors by mechanical contractors during field installation (800 electrical terminations and 40 pneumatic connections)
- Eliminates enclosures with a total of over 40 penetrations
- Reduces the PLC inputs and outputs by 40, thereby reducing the size of the main panel
- Is rated IP67 (Dust tight and submersible to 1 meter)
- Operates at 24 VDC
The fieldbus system we employed is the PLC distributed I/O system (remote I/O modules) that is connected to the PLC using network called fieldbus. Typical fieldbus examples: Profibus, CAN, Modbus, ControlNet, DeviceNet, Ethernet I/P. At our customer, Res-Kem used Ethernet I/P (I/P=Industrial Protocol) fieldbus. Each block must have communication adapter that is connected to the PLC network. At our customer, the Ethernet Adapter connected to the panel Ethernet switch. In addition to I/O blocks, the vendor Res-Kem uses, has solenoid blocks that are acting like digital outputs and are attached to the I/O system. Each block (fieldbus system) is powered from 24 VDC power supply providing power for backplane.
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| Greensand Filters During Factory Testing Showing Location of Each Fieldbus Block |
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| Typical Solenoid Panel WITHOUT Limit Switch Terminations |
More About Fieldbus:
Fieldbus is an industrial network system for real-time distributed control. It is an efficient way to connect instruments in a manufacturing plant.
From Wikipedia, "A complex automated industrial system — such as
manufacturing assembly line — usually needs a distributed control system—an
organized hierarchy of controller systems—to function. In this hierarchy, there
is usually a Human Machine Interface (HMI) at the top, where an operator can
monitor or operate the system. This is typically linked to a middle layer of
programmable logic controllers (PLC) via a non-time-critical communications
system (e.g. Ethernet). At the bottom of the control chain is the fieldbus that
links the PLCs to the components that actually do the work, such as sensors,
actuators, electric motors, console lights, switches, valves and contactors."
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1 comment:
A process PLC Control Panles system is made up of a group of electronic devices that provide stability, accuracy and eliminate harmful transition statuses in production processes. Operating systems can have different arrangements and implementation, from energy supply units to machines. As technology quickly progresses, many complex operational tasks have been solved by connecting programmable logic controllers and a central computer.
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