Bezprzewodowa komunikacja w procesie - produkty i rozwiązania

Jörg Brasas
Wireless in infrastructure and process

Wireless I/O
Digital Signals
0 … 250 V AC/DC
Analogue Signals
0 … 20 mA, 4 … 20 mA
0 … 10 V, HART
Wireless Ethernet
Wireless Serial
RS-232 RS-422 RS-485
Ethernet

Applications Technology
longnear
fast
slow
Operation distance
Dataupdatetime
Factory automation
Infrastructure
Process automation
WLAN

 4…20mA signal represents
a physical measurement
range
 e.g., 0…100°F
 a signal less than 4mA or
greater than 20mA indicates
a problem
what is a 4…20mA signal?
20mA
4mA
4…20mA signal
time

 HART is digital data
superimposed onto a
4…20mA signal
 FSK modulation
(frequency shift keying)
 1200bps
what is HART?
HART stands for Highway Addressable Remote Transducer
20mA
4mA
1
11
1 1
0 0
0
0
4…20mA signal
HART signal
time
1200Hz
2200Hz

pressure | temperature | level | flow | pH | valves | gas detectors
HART devices
most process measurement instruments are HART capable
the HART protocol provides
access to many additional
features and capabilities
3.5 psi 4 process variables
device set up
calibration
device diagnostics
4…20mA represents the process variable

HART communication
HART communication
HART device
(slave)
12mA
(master)
primary
(master)
secondary
PC
PLC
DCS
PAM

Unlock your data
Flow
 process media density
 absolute pressure and
temperature
 totalized flow
Pressure
 cell temperature
 static pressure
 sensor status
Valve Positioner
 actual valve position
feedback
 adjust for mechanical wear
 sensor status
Temperature
 ambient temperature
 cold junction temperature
 sensor breakage
pH
 temperature measurement
 sensor health
Level
 sensor status
 high and low alarm setpoints

HART technology
the world’s most broadly supported protocol for the process industry

WirelessHART
unlocks stranded data and add new measurement points
WirelessHART
adapter
retrofit wired instruments
to WirelessHART
may be loop, line, or
battery powered
WirelessHART
device
add new measurement or
control devices without any
wires
may be line or battery
powered
WirelessHART
gateway
manages the
WirelessHART network
connects to the control
system

RAD-WHG/WLAN-XD
the world’s first DIN rail mount WirelessHART gateway
connect via
10/100Mbps port
integrated 802.11b/g client
access process data via
HART IP, Modbus TCP, FDT/DTM
(supports up to 250 field devices)
configure with a web browser
environmental
-40…70°C
ATEX, IECEx, CSA Zone 2

RAD-WHG/WLAN-XD
installation options
to
control
system
WLAN disabled
Ethernet connection to
control system
to
control
system
WLAN to
HMI or field
maintenance
WLAN maintenance port
Ethernet connection to control system
WLAN connection to HMI, maintenance PC
or tablet
WLAN to
control
system
WLAN backhaul
WLAN connection to control
system

RAD-WHA-1/2NPT
WirelessHART adapter offers flexible connections in the field
power with
loop power (2.3V loop drop)
11…30VDC (isolated)
mechanical
removable antenna (N-type connector)
rugged cast aluminum housing
1/2NPT or M20 fitting
environmental
-40…70°C
ATEX, IECEx, CSA Zone 2
connect
up to 4 HART devices
measure standard 4…20mA loops

RAD-WHA-1/2NPT
installation options
24V
multidrop
connect up to 4 HART
devices
WHA is 24V powered
WHA supplies loop power for
the HART devices
24V
4…20mA
WHA is 24V powered
WHA supplies loop power for
a 4…20mA device
WHA reports 4…20mA loop
value as PV
loop powered
retrofit an existing device
the loop stays intact
WHA is loop powered
to DCS
line powered
retrofit an existing device
the loop stays intact
WHA is 24V powered
24V
to DCS
retrofit existing installations add new measurement points

HART sensors connected wirelessly
Wireless HART
 WirelessHART gateway and adapter
 Compatible with other manufacturers
 Up to 250 network devices
 Distances up to 250 m
 4 analog HART inputs
Wireless I/O

Redesign
Wireless MUX
 Modernised future-proof hardware
platform
 Based on the latest Bluetooth 4.0
standard
 Higher accuracy of the analog channels
 Unified RSMA antenna connector
 Production optimisation for larger
quantities

The wireless signal cable
Wireless MUX
 Range of 50 m - 100 m in
industrial halls and over 200 m
outdoors
 Transmission time
≥ 10 ms
 16 digital inputs/outputs
 2 analog inputs/outputs
Wireless I/O

Target market : Machine and plant construction
Application fields
 Automated crane control
 Warehouse logistics
 Building industry
 Material handling
 Waste water plants
 Metal processing
 Vehicles and machines
Replacement
 Slip rings
 Conductor rails
 Drag chains
 Cable drums
 Cable conduit
 Special cables

Composting machines
Application Machine building
Application:
 To speed-up the composting process a hose
reel is connected to the windrow turner
 Hose length ca. 200 m
 Switching on and off of the hydraulic motor,
detection of the flow rate
Benefit:
 Easy installation and operation
 Easy integration of existing and new signals
into the machine control
 Interference-free parallel operation

Metal processing
Application Process industry
Application:
 Forming process of tubes
 35 machines over 2 floors
 Interference-prone cable between
the control panel and machine
Benefit:
 Reducing downtime
 Wear-free and robust communication
 Easy startup
 Coexistence with the existing WLAN

Metal processing and transport
Application:
 Processing of recycled steel
 Communication between crane and
control room (trailing cable replacement)
 10 independent crane
 Strong vibration and corrosive
atmosphere
Benefit:
 Easy startup

Only the cable for the
power supply is
necessary.
Application:
 Replacement of cable conduits
 Position detection of position
switch
Benefit:
 Wear-free and robust
communications
 Easy start-up
 Coexistence with the existing
WLAN
Handling robots
Application Automobile industry

Trusted Wireless 2.0
Technology for the industry
 Especially developed by Phoenix Contact
for industrial use
 Robust and secure communication
 Long distances
 Excellent
Coexistence features
Wireless Serial
Wireless I/O

Field of applications
Extensive infrastructure plants
 Water / Waste water
 Material handling / Traffic
engineering
 Process industry
 Energy

Trusted Wireless 2.0
Technology Video
Wireless Serial
Wireless I/O

Setup of the
wireless connection
Easy signal
distribution
Signal
multiplication
I/O Mapping – Signal distribution without programming

RSSI-Signal
Product details radio module

RSSI-Signal
0…3 V DC
RSSI = Received Signal Strength Indicator
Terminal 2.1 (+) and 2.2 (-)

LED-Bargraph RSSI
Point-to-Point connection Point-to-Multipoint connection
Master = only yellow LED ON!

Latency time point-to-point
* I/O-Data mode: The telegram length depends on the number of I/O- extension modules
* Serial-Data mode: The telegram length depends on the connected serial end device

Radioline
One devices – a huge number of applications

RS-485 Multiplexer
 Multipoint-Multiplexer operation
based on RS-485 interface
 Up to 99 stations per network
 I/O-to-serial operation as Modbus
RTU buscoupler as slave
 1200 meter over RS-485
2,4 GHz Wireless Head module
 For license-free 2,4 GHz ISM
frequency band all over the
world
 Adjustable transmit power
0…20 dBm and high receiver
sensitivity
 Ranges up to 5 km
868 MHz Wireless head module
 For license-free 868 MHz ISM
frequency band in Europe
 Adjustable transmit power
sensitivity
900 MHz Wireless head module
 For license-free 900 MHz ISM
frequency band (America and
Kanada)
 Adjustable Transmit power
sensitivity
Radioline
Worldwide use in industrial applications

A huge number of signals
RS-232
RS-485
DOR
AIAO
DI DO
TEMP
CNT

Overview I/O- Extension modules
Radioline
Product type Name Art.-No.
Analog 4 analog input RAD-AI4-IFS 2901537
4 Pt-100 input RAD-PT100-4-IFS 2904035
4 analoge output RAD-AO4-IFS 2901538
Digital 4 digital input RAD-DI4-IFS 2901535
4 digital relay output RAD-DOR4-IFS 2901536
8 digital input or
2 impuls input
RAD-DI8-IFS 2901539
8 digital transistor output RAD-DO8-IFS 2902811
Analog /
Digital
1 analoge input / output, 2 digital wide
range input and outout
RAD-DAIO6-IFS 2901533

Radioline
I/O-Mapping over the air

Radioline
I/O-Mapping wire-connected
RS-485

Radioline
I/O-Mapping - intermedia
Features:
- Intermedia I/O Mapping
- Connection to wireless master

Application examples
Existing cables

Radioline
Expand the range of coverage

Wireless networking of serial interfaces
Radioline
 High transmission reliability
 Range of up to several
kilometers
 Comprehensive diagnostic
options
 Up to 250 network devices

Wireless networking of serial interfaces
Radioline operation mode
 Serial data mode
 Replacement for RS-232/485 cable
 Point-to-point, star or mesh network
 Data rate up to 115,2 kBit/s
 Profibus data rate up to 93,75 kbps
RS-232
RS-485
RS-232
RS-485

I/O-Integration via Modbus RTU protocol
 PLC-Modbus RTU mode
 Digital/analog I/Os can be linked to a
controller (Modbus RTU)
 Easy I/O-Integration
 Internal Watchdog for monitoring the
modbus communication

Modbus Master
Modbus Slave
Modbus Register
SignalSignal
Signal
SignalSignal
Sensor /
Aktor
Sensor /
Aktor
PLC/Modbus RTU mode

I/O-Integration via Modbus RTU protocol
Radioline functional block library for PCWORX
 PCWORX functional block library
 Cost free Radioline library
 Quick error localization, thanks to
alarm messaging in the event of an
error
 Entire system overview from the
control room
 Signal strength, error status

Wireless impuls transmission
 Because of delay times (200 ms … 2 s) the digital channels
are only suitable for state transfers
 For fast impuls transmission < 100 Hz
 RAD-DI8-IFS use in counter mode
 32-Bit Register readable via modbus PLC
Radioline PLC/Modbus RTU mode
CNT

Radioline
Flexible network structures
 Point-to-point connection
 Star networks
 Mesh networks and line
structures
Wireless RS-485 based

Radioline
Coexistence
 Network-ID:
 The Net-ID is a parameter for identifying the radio modules in a network
 Only radios with the same NET-ID can connect to each other
 RF-Band:
 Group which consists of individual frequencies
 Various RF bands use different frequencies
 WLAN-Blacklist:
 Allows manual hiding of WLAN frequencies

Radioline
Coexistence
M
S
Net-ID = 10
Net-ID = 10
M
S
Net-ID = 35
Net-ID = 35
M
S
Net-ID = 120
Connected! Connected! Disconnected!
RF-Band = 1 RF-Band = 3 RF-Band = 5
Net-ID = 135

Radioline
Unique NET-ID with Confstick
Master ID=01 RS ID=02
RS ID=03
Read in the device configuration via
Confstick
1. Insert the Configstick in the S-
Port
2. Push the Set-button for 1 second
3. Parameter read in is started
4. DATA LED lights up once, read in
process has been completed
5. Remove the Confstick and retry it
for each radio of the network

Network-ID and RF-Band
Factory
setting
Conf stick PSI-CONF
Software
Net-ID 127
≥ 128…..
(unique ID)
1 bis 127
(adjustable)
RF-Band 2,4 GHz
RF-Band 868 MHz
1
2
3, 5 or 7
1
1 … 8
1 … 14
Default
Unique
configuration is
stored in Conf
stick!
Adjustable by
user!

Automatic high bay warehouse
Application Warehouse logistics
Application:
 Communication of motion tasks
between shuttle and channel PLC
 Not enough space for using light
barriers
 Distance of ca. 250 m
Benefit:
 Coexistence with the existing WLAN
 Coexistence of 100 radios links in one
storage

Automatic high bay warehouse
Application Warehouse logistics

Monitoring pump station
Application Water / Wastewater
1,2 km
Application:
 Underground cable partially damaged
 Recording of status signals, pump
delivery rate, water flow meter pulses
Benefit:
 Easy start up
 License-free solution – no running
costs
 Quick, cost- effective alternative
solution to complex cable laying

Monitoring of remote stations
Application:
 Cable damaged, cable laying very complex
 Central monitoring of remote stations (no lign of
sight)
 Recording of status signals, pump delivery rate,
water flow meter pulses, liquid level
Benefit:
 Easy startup
 Private wireless network – provider independent
 Quick, cost- effective alternative solution to
complex cable laying

Monitoring of remote stations
868 MHz
2,4 GHz
Control room
Pump station
Transfer station
Deep well
Deep well
High-level tank
High-level tank

Traffic control system
Application Traffic engineering
Application:
 Control of sign boards for traffic
jam information
 Wireless communication between
23 control points
 Cable installation impossible
during highway traffic
Benefit:
 Easy startup
 License-free solution – no running
costs
 Reliable communication

Monitoring of conveyor belts
Application Material handling
Bitola - Macedonia
• ca. 10 km conveyor system
• 6 wireless systems
• Redundancy to existing cable

Mobile conveyor belts
Application Material handling
Application:
 Monitoring (Temperature, status, alarm
signals) and control of movable
conveyor belts and stacker
 Mesh network with 25 repeater slaves
 Area size 5 km²
Benefit:
 Replacement of expensive special
cable drums
 Bridging large distances and obstacles
 Central monitoring of local information
 Flexibility in changes

Foundry
Energy management solution
Application:
 Central Energy measurement of induction
furnaces, hydraulic presses, etc.
 Archiving of data for identification to the
tax authorities
 Cable laying very complex
Benefit:
 Simple integration of additional measuring
devices
 Reliable transmission even without line of
sight thanks to mesh networking capability

Simple and flexible adaption
Radioline
 Modular expandable with up to 32 I/O
modules
 Modules can be inserted and removed
even during operation (hot-swappable)
 Extended temperature range
-40…+70°C
 Galvanic channel to channel isolation

Long distance alternative – if 2,4 GHz fails
Radioline 868 MHz
Opportunities:
 Wide ranges up to 20 km
 Shorter distances in applications where 2.4 GHz
fails quickly (e.g. forest, urban environment)
 Better wave propagation
Applications:
 Non time critical and low data rates
 Energy, Water, Gas, Traffic
 Water Reservoirs
 Port / harbour logistics
 Mining

2.4 GHz – no LOS
2.4 GHz – LOS
868 MHz – no LOS
868 MHz – LOS
LOS = Line of Sight

Diagnostic and extended configuration options
Radioline
 Safe parallel operation of multiple
networks
 Extensive diagnostics of all network
devices
 Setting extended network
parameters
 Saving customer-specific
configurations

Radioline
Wireless coverage
The reachable distance depends on the following parameters:
Network structure (using repeaters)
Selected antenna (Gain, Omni, Panel)
Transmission power
Data rate over the air (OTA)
Environmental conditions

Radioline
Coverage 2,4 GHz
2 dBi Omni
up to 300 m
Up to 3000 m
> 5000 m
The range can be considerably exceeded or fallen below and depends on the
environment, OTA data rate and antenna technology!
6 dBi Omni
Up to 1500 m
8 dBi Panel
19 dBi Parabol

Radioline
Coverage 868 MHz
The range can be considerably exceeded or fallen below and depends on the
environment, OTA data rate and antenna technology!
4 dBi Omni
4 dBi Panel
8 dBi Yagi 12 dBi Yagi
Up to 8 km
Up to 10 km
Up to 15 km > 20 km

Antenna installation in Ex areas
Zone 2
Zone 0,1,2
Ex i
Wireless Accessories

Refinery / Oil tanks
Application Oil & Gas industry
ZONE 2
Application:
 Monitoring of valve positions
 Early detection of process errors
 Remote I/O signals
Benefit:
 Cost-effective alternative to 40 km data
cable
 Complete solution from one source
 Flexible customization and extension
2,1 km
1,8 km

Refinery / Oil tanks
Solutions for Oil & Gas industry
Complete solution from one source:
 More then 1200 Inline I/Os
 150 radios, 150 bus couplers
 Devided in 7 mesh networks

Oil production
Application Oil & Gas industry
Application:
 Monitoring of pump stations
 Detection of valve positions
 Detection of temperature, pressure, flow
 Early detection of system faults
 Remote I / O signals
Benefit:
 Cheap diagnosis and efficient monitoring
 Complete solution from one source
ZONE 2

Oil production
Solutions for Oil & Gas industry
Complete solution
From one source:
 200 radios
 600 I/O- modules
 Divided into 8 mesh networks

Chemical park
2,4 km
Tower
Master
Application:
 Monitoring of 20 pump stations
 Recording of status and flow rate of
pump stations
Benefit:
 Easy startup
 License-free wireless solution - no
running costs
 Quick, cost- effective alternative
solution to complex cable laying

Chemical park

River monitoring in power plants
Application Power generation
Application:
 Data transfer between the cooling water outlet and power plant
 Temperature monitoring of rivers
 Continous control and reporting of measurement data (burden of
proof, documentation required)
 Cable laying very complex
Benefit:
 Bridging big distances and obstacles
 Central recording and archiving
 Cost savings of around 60 to 100 € per meter
 Autarkic power supply
Power plant Hamm

River monitoring in power plants

PV power plant
Application:
 Monitoring of generator junction boxes, inverters, power
supply, weather station, etc.
 Measured value transmission in widely ramified free field
installations
Benefit:
 Simple upgrade / expansion of the communications
infrastructure
 Robust data transmission in EMC disturbed environments
 Saving cost-intensive earthworks

Solarcheck via Radioline
Solutions for PV industry

Profibus cable replacement
Configuration via PSI-CONF Software

Wastewater plant
Application:
 Position detection of 8 scraper bridges
 I/O integration in Profibus control system
Benefit:
 Fast pulse detection by the pulse input
module RAD-DI8-IFS
 License-free solution – no running costs
 Wear-free and reliable radio transmission
(failure rate with sliding contacts > 30%)

Wastewater plant
Application Water/Wastewater
Application:
 Sludge level measurement in 4 secondary
clarifiers
 Pump monitoring in rake sand trap system
 Volume measurement in pressure pipe line
 Signal transmission between WWTP and
slaughterhouse (distance 200 m)
Benefit:
 Wireless technology used in all parts of the
WWTP
 Wear-free and reliable radio transmission
(failure rate with sliding contacts > 30%)
 Interference-free parallel operation of
multiple radio systems

Approved accessories
2903219 2,4 GHz
2701186 2,4 / 5 GHz
2702137 868 MHz
2702136 868 MHz 2702198 0,7…6 GHz
Wireless Accessories

Determining the conditions
Planning
 Type of the interface (I/O, RS-232 /485/422)
 Data protocol (Modbus, Profibus, SC1000, etc.)
 Maximum permissible response times (ms or s)
 Max. number of network devices
 Max. distance, geographical location of stations (GPS
coordinates)

Feasability analysis and test
1,67 km
Link test
RSSI 2,1 V
Link test
RSSI 2,7 V
Link test
RSSI 1,1 V
Transfer station
Deep well
High-level tank
Pump station
Transfer station
Pump station
High-level tank

Radioline test – Water station
760 m
Obstacles
 European spruce
Water treatment plant
 868 MHz (Master)
 9,6 kbps
 8 dBi Yagi
Water well
 868 MHz (Slave)
 9,6 kbps
 8 dBi Yagi
2.27 V

Radioline test – Waste water station
2760 m
1.65 V
Master
 868 MHz
 9,6 kbps
 12 dBi Yagi
Slave
 868 MHz
 9,6 kbps
 4 dBi OMNI
Obstacles
 Trees
 Buildings
 A44 motorway bridge

Radioline test – Tunnel Antwerpen
Information about the tunnel:
 Length ca. 1400 m
 4 traffic lanes each 3,75 m wide
 Hight ca. 5 m
 No free lign of sight
Test results:
 RSSI signal 2,4 GHz: 1,3 V (OMNI)
2,5 V (PANEL)
 RSSI signal 868 MHz: 2,3 V (OMNI)
2,9 V (PANEL)

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