FreeWave I/O for Rockwell Curt Goldman Market Manager, Utilities Randy MaesRockwell Specialist Bret Dianich Western Region BDE Nichole Pettway Eastern

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

04/10/23© 2011 FreeWave Technologies, Inc. 3

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


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


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



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 RockwellFreeWave 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

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


Wired I/O Expansion


Wireless I/O Expansion


FreeWave I/O for Rockwell:Applications

Electric PowerWater Purification

Wastewater Treatment

FreeWave I/O for Rockwell:Applications

Electric PowerWater Purification

Wastewater Treatment


Typical Applications in Electric Power:

• Circuit breaker monitoring

• Transformer condition monitoring

• Switch monitoring

FreeWave I/O for RockwellApplications


Typical Applications with Water:

• Pump control *

• Water tower monitoring *

• Irrigation



Typical Applications with Wastewater:

• Lift Stations *

• Water quality monitoring

• Chemical pumps




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



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



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



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



Compatibility


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


FGR2-IO, Modbus RTU and Allen-Bradley PLC’S

Compatibility


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


PLC overview


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



• 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


Micro800 family

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

PLC overview


MicroLogix family

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

PLC overview


SLC500 family

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

PLC overview


CompactLogix family

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…)

PLC overview


• 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


• Micro830 wired I/O expansion



• MicroLogix 1500LSP with wireless I/O



• SLC5/05 with multi-drop wireless I/O



• CompactLogix w/ 1769-SM2


Questions?


• CompactLogix w/ MicroLogix as Modbus RTU Master



• CompactLogix w/ MicroLogix as Modbus RTU Master


Documents

FreeWave I/O for Rockwell Curt Goldman Market Manager, Utilities Randy MaesRockwell Specialist Bret Dianich Western Region BDE Nichole Pettway Eastern