FreeWave I/O for Rockwell
Curt Goldman
Market Manager, Utilities
Randy Maes
Rockwell Specialist
Bret Dianich
Western Region BDE
Nichole Pettway
Eastern Region BDE
February 27, 2012
Application
examples
FreeWave I/O for Rockwell
Agenda
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
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FreeWave I/O for Rockwell:
Technology Overview
FreeWave I/O for Rockwell
Technology Overview
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
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FreeWave I/O for Rockwell
Technology Overview
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
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FreeWave I/O for Rockwell
Technology Overview
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.
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FreeWave I/O for Rockwell
Wireless I/O for Rockwell
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
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Wireless I/O for Rockwell
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
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Wireless I/O for Rockwell
Wired I/O Expansion
Wireless I/O for Rockwell
Wireless I/O Expansion
FreeWave I/O for Rockwell:
Applications
Electric Power
Water Purification
Wastewater Treatment
FreeWave I/O for Rockwell
Applications
Typical Applications in Electric Power:
• Circuit breaker monitoring
• Transformer condition monitoring
• Switch monitoring
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FreeWave I/O for Rockwell
Applications
Typical Applications with Water:
• Pump control *
• Water tower monitoring *
• Irrigation
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FreeWave I/O for Rockwell
Applications
Typical Applications with Wastewater:
• Lift Stations *
• Water quality monitoring
• Chemical pumps
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FreeWave I/O for Rockwell
Applications
FreeWave I/O for Rockwell
Applications
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
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FreeWave I/O for Rockwell
Applications
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
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FreeWave I/O for Rockwell
Applications
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 longrange systems
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FreeWave I/O for Rockwell
Applications
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
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FreeWave I/O for Rockwell
Applications
Compatibility
FreeWave I/O for Rockwell
Applications
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
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FGR2-IO, Modbus RTU and Allen-Bradley
PLC’S
Compatibility
FreeWave I/O for Rockwell
Applications
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
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PLC overview
FreeWave I/O for Rockwell
Applications
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
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FGR2-IO, Allen-Bradley compatibility
• Micro 800 Family
Micro 830
•
•
Micro 850 (when released)
• SLC
• MicroLogix
•
•
•
•
1100
1200
1400
1500
• CompactLogix
•
5/03
•
1769-L23
•
1769-L35E
•
5/04
•
1769-L23E
•
1769-L35E
•
5/05
•
1769-L31
•
1769-L35CR
•
1769-L32E
•
1769-L43
•
1769-L32C
•
1769-L45
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PLC overview
Micro800 family
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PLC overview
• 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
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PLC overview
MicroLogix family
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PLC overview
• 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
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PLC overview
SLC500 family
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PLC overview
• 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
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PLC overview
CompactLogix family
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Application
examples
PLC overview
• 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…)
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PLC overview
• CompactLogix with MicroLogix 1100/1400
•
•
MicroLogix communications run independently
The MicroLogix and CompactLogix don’t have to be colocated (networked via EtherNet/IP)
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Application examples
• Micro830 wired I/O expansion
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Application examples
• MicroLogix 1500LSP with wireless I/O
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Application examples
• SLC5/05 with multi-drop wireless I/O
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Application examples
• CompactLogix w/ 1769-SM2
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Questions?
Application examples
• CompactLogix w/ MicroLogix as Modbus RTU Master
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Application examples
• CompactLogix w/ MicroLogix as Modbus RTU Master
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