1. 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

2. Application examples

3. FreeWave I/O for Rockwell Agenda
Technology Overview
FreeWave I/O Products: I/O Expansion
Applications for FreeWave I/O and Rockwell
Compatibility Between Allen-Bradley PLC’s and FreeWave I/O
© 2011 FreeWave Technologies, Inc.
3/25/2017

4. FreeWave I/O for Rockwell: Technology Overview

5. 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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6. 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
© 2011 FreeWave Technologies, Inc.
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7. 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.
© 2011 FreeWave Technologies, Inc.
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8. FreeWave I/O for Rockwell

9. 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
© 2011 FreeWave Technologies, Inc.
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10. 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
© 2011 FreeWave Technologies, Inc.
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11. Wireless I/O for Rockwell
Wired I/O Expansion

12. Wireless I/O for Rockwell
Wireless I/O Expansion

13. FreeWave I/O for Rockwell: Applications Electric Power Water Purification Wastewater Treatment

14. FreeWave I/O for Rockwell Applications
Typical Applications in Electric Power:
Circuit breaker monitoring
Transformer condition monitoring
Switch monitoring
© 2011 FreeWave Technologies, Inc.
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15. FreeWave I/O for Rockwell Applications
Typical Applications with Water:
Pump control *
Water tower monitoring *
Irrigation
© 2011 FreeWave Technologies, Inc.
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16. FreeWave I/O for Rockwell Applications
Typical Applications with Wastewater:
Lift Stations *
Water quality monitoring
Chemical pumps
© 2011 FreeWave Technologies, Inc.
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17. FreeWave I/O for Rockwell Applications

18. 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
© 2011 FreeWave Technologies, Inc.
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19. 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
© 2011 FreeWave Technologies, Inc.
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20. 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 long- range systems
© 2011 FreeWave Technologies, Inc.
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21. 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
© 2011 FreeWave Technologies, Inc.
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22. FreeWave I/O for Rockwell Applications

23. Compatibility

24. 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
© 2011 FreeWave Technologies, Inc.
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25. FGR2-IO, Modbus RTU and Allen-Bradley PLC’S

26. Compatibility

27. 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
© 2011 FreeWave Technologies, Inc.
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28. PLC overview

29. 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
© 2011 FreeWave Technologies, Inc.
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30. FGR2-IO, Allen-Bradley compatibility
Micro 800 Family
Micro 830
Micro 850 (when released)
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-L35CR
1769-L43
1769-L45
© 2011 FreeWave Technologies, Inc.
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31. Micro800 family PLC overview 31 © 2011 FreeWave Technologies, Inc.
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32. 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
© 2011 FreeWave Technologies, Inc.
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33. MicroLogix family PLC overview 33 © 2011 FreeWave Technologies, Inc.
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34. 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
© 2011 FreeWave Technologies, Inc.
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35. SLC500 family PLC overview 35 © 2011 FreeWave Technologies, Inc.
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36. 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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37. CompactLogix family PLC overview 37 © 2011 FreeWave Technologies, Inc.
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38. Application examples

39. CompactLogix with 1769-SM2 module
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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40. CompactLogix with MicroLogix 1100/1400
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)
© 2011 FreeWave Technologies, Inc.
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41. Micro830 wired I/O expansion
Application examples
Micro830 wired I/O expansion
© 2011 FreeWave Technologies, Inc.
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42. MicroLogix 1500LSP with wireless I/O
Application examples
MicroLogix 1500LSP with wireless I/O
© 2011 FreeWave Technologies, Inc.
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43. SLC5/05 with multi-drop wireless I/O
Application examples
SLC5/05 with multi-drop wireless I/O
© 2011 FreeWave Technologies, Inc.
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44. Application examples CompactLogix w/ 1769-SM2 44
© 2011 FreeWave Technologies, Inc.
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45. Questions?

46. Application examples CompactLogix w/ MicroLogix as Modbus RTU Master
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47. Application examples CompactLogix w/ MicroLogix as Modbus RTU Master
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