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Factory & machine automation

PACs, distributed I/O and fieldbus modules for machines, production lines and process control.

Factory & machine automation
Photo: Charly Birdsinger · CC0 · Wikimedia Commons

In factory and machine automation the controller, the I/O and the network are usually chosen together. ICP DAS covers all three: programmable automation controllers (PACs) that run IEC 61131-3 programs or your own software, I/O that sits in the controller's backplane or out on the machine, and communication modules for the fieldbuses already used on the line.

Typical tasks

  • Controlling a machine or production cell with a PAC instead of, or next to, a conventional PLC
  • Adding I/O to an existing PLC or SCADA system over Modbus RTU, Modbus TCP, EtherNet/IP, PROFINET or PROFIBUS
  • Distributed I/O close to sensors and actuators to reduce cabling
  • Motion control and synchronised I/O over EtherCAT or Motionnet
  • Collecting machine data for OEE, condition monitoring and traceability

Controllers

ICP DAS PACs are available with different operating systems and programming models. Win-GRAF PACs work as soft PLCs programmed in the IEC 61131-3 languages, such as ladder diagram, function block diagram and structured text. Linux and Windows PACs suit applications that need custom software, a local database or an HMI on the controller itself, and MiniOS7 PACs are compact controllers for simpler, deterministic tasks. Many models have slots for I/O cards from the I-8K/I-87K and I-9K/I-97K families, so the controller and its local I/O form one unit.

Distributed and fieldbus I/O

When I/O has to be spread across a machine or a line, the choice usually follows the network:

  • RS-485 (M-7000, I-7000, tM series): Modbus RTU or DCON on a two-wire bus. Simple, robust and suited to long cable runs.
  • Ethernet (ET-7000, ET-7200, ET-2200, tET/tPET): Modbus TCP and configuration from a web browser. The ET-7200 and ET-2200 series have a two-port switch for daisy-chaining, and PoE versions take power and data over one cable.
  • Fieldbus I/O: EtherCAT, CANopen, PROFIBUS, PROFINET, DeviceNet and EtherNet/IP slave modules for integration into an existing master.

Gateways and converters

Machines rarely use a single protocol. Industrial communication modules convert between serial interfaces and Ethernet, between Modbus and CAN, CANopen, PROFIBUS, PROFINET or EtherNet/IP, and connect older RS-232 equipment to a modern network. Industrial Ethernet switches, including PoE and ring-redundant types, complete the network on the machine.

Motion control

For axes and positioning, ICP DAS offers EtherCAT-based PAC solutions, Motionnet modules and boards, and PC-based motion control boards for machines built around an industrial PC.

Example: condition monitoring on an existing machine

A common retrofit leaves the existing PLC in charge of the machine. An Ethernet I/O module from the ET-2200 series is added next to it to measure motor temperatures with RTD inputs and count cycles on a digital input. SCADA or an edge controller reads the module over Modbus TCP, so the PLC program does not have to change. If the values are later needed in an MES or a cloud system, a communication server converts them to OPC UA or MQTT.

What to check before you choose

  • Which protocol the master (PLC, PAC or SCADA) uses, and whether the I/O should be a Modbus slave or a fieldbus slave
  • Signal types and counts: digital inputs and outputs, relays, analog voltage and current, RTD, thermocouple and counters
  • Isolation and surge protection between field wiring and the controller
  • Operating temperature range, mounting on DIN rail or in a panel, and the supply voltage
  • Cycle time: polled Modbus is fine for most process data, while fast motion and synchronised I/O call for EtherCAT

If you are unsure which combination fits, send us a short description of the machine or line and the existing controller, and we will suggest a set of modules.

Products for this application

PET-7017-10 CR
PET-7017-10 CR PET-7017-10 PoE Ethernet I/O Module, 10/20-ch Analog Input

The PET-7017-10 is a PoE-powered Ethernet analog input module for engineers who need voltage or current measurement on a networked I/O node. Its inputs can be set as 10 differential or 20 single-ended channels in software, and each channel can be given its own range, so one module can serve mixed sensor types on the same network.Each channel offers a choice of voltage ranges from ±150 mV to ±10 V and current ranges of ±20 mA, 0 ~ 20 mA and 4 ~ 20 mA, selected with jumpers. Resolution is 16-bit, and the module has two sampling modes: normal mode at 10 Hz total and fast mode at 50 Hz total. Open wire detection is available for 4 ~ 20 mA inputs, and differential channels are rated for 240 Vrms overvoltage protection.Configuration and monitoring are handled through a built-in web server with Web HMI, and the module supports Modbus TCP and Modbus UDP. Access is controlled by ID, password and IP filter. The unit is powered either from PoE (IEEE 802.3af, Class 1) or from a +12 ~ +48 VDC terminal block, and it mounts on a DIN rail.ApplicationsBuilding automationFactory automationMachine automationRemote maintenanceRemote diagnosisTesting equipment

Κανονική τιμή: 286,00 € per piece · volume discount from 10 pcs
BNET-2310M CR
BNET-2310M CR BNET-2310M BACnet/IP I/O Module, 4-ch AI, 2-ch AO, 4-ch DI, 4-ch DO

The BNET-2310M CR is a remote I/O module that brings 4 analogue inputs, 2 analogue outputs, 4 digital inputs and 4 digital outputs onto a BACnet/IP network. A BMS or BACnet/IP client can read field sensor signals directly over Ethernet and command connected analogue or digital output devices, without a separate gateway.The module operates as a BACnet/IP Server and also supports Foreign Device functionality. It can register with a specified BBMD to receive BACnet/IP messages forwarded across different IP subnets, which suits multi-floor buildings, multi-building facilities, industrial sites and larger BEMS installations.Configuration is handled through a built-in web server, so the module can be set up from a standard web browser. Configuration files can be imported and exported for backup and repeat deployments. The CR ordering code is the RoHS-marked variant.ApplicationsHVAC control and monitoring in building automationLighting and energy managementBMS and BEMS integration via BACnet/IPMulti-floor buildings and multi-building facilitiesIndustrial sites with BACnet/IP field I/O

Κανονική τιμή: 271,00 € per piece · volume discount from 10 pcs
CAN-2012C CR
CAN-2012C CR CAN-2012C CANopen Slave Module, 16-bit 16-ch Analog Input

The CAN-2012C is a CANopen slave analog input module that brings 16-bit measurements onto a CAN bus network. It provides 8 differential or 16 single-ended inputs, selectable in software, and covers voltage ranges of ±10V, ±5V, ±2.5V and 0~10V as well as current ranges of ±20mA, 0~20mA and 4~20mA. Each channel can be configured individually.Built for CANopen networks, the module follows CiA 301 v4.02 and CiA 401 v2.1 and operates as an NMT slave with Node Guarding and Heartbeat error control. A default EDS file is provided for use with standard CANopen master software, and the module has passed the CiA CANopen conformance test tool, which simplifies commissioning with masters from ICP DAS or other manufacturers.Electrical features include 4 kV contact ESD protection on each channel, support for a 10 to 30 VDC supply, and isolation rated at 2500 Vrms for photo-coupling and 3000 VDC for DC-to-DC. The module mounts on DIN-rail and operates from -25 to +75 °C.ApplicationsIndustrial machinery controlFactory automationPackaging machine controlRemote data acquisitionEnvironmental monitoringVehicle control systemsMedical equipment control

Κανονική τιμή: 308,00 € per piece · volume discount from 10 pcs
CAN-2015C CR
CAN-2015C CR CAN-2015C CANopen Slave Module, 8-ch RTD Input

The CAN-2015C CR connects eight RTD sensors to a CANopen network as a slave device. Each channel accepts 2-wire or 3-wire RTD sensors, with 16-bit resolution and an accuracy of +/-0.05% FSR. Engineers can read RTD values or configure the module over standard CANopen messaging.The module follows CiA 301 v4.02 and CiA 401 v2.1 and has passed validation with the CiA CANopen Conformance Test tool. A default EDS file is provided, so it can be added to a standard CANopen master with minimal configuration effort. It also works with the CANopen masters offered by ICP DAS.Diagnostic and protection features include open wire detection, individual channel configuration, a built-in 120Ω terminal resistor and 4 kV contact ESD protection on each channel. The unit runs from +10 ~ +30 VDC and is intended for DIN-rail mounting, with an operating range of -25 ~ +75 °C.ApplicationsIndustrial machine controlFactory automationPackaging machine controlRemote data acquisitionEnvironmental monitoringVehicle control systemsMedical equipment control

Κανονική τιμή: 343,00 € per piece · volume discount from 10 pcs

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