MOXA Case Studies Boiler Control System for Plastic Manufacturing Applications

	Boiler Control System for Plastic Manufacturing Applications MOXA

Boiler Control System for Plastic Manufacturing Applications

MOXA

Technology Category	Networks & Connectivity - Gateways
Applicable Industries	Plastics
Applicable Functions	Process Manufacturing
Use Cases	Remote Control
Challenge	Factory automation applications must be equipped to handle and monitor the myriads of information from attached devices. For plastic manufacturing applications, the boiler control system plays a critical role by gathering and regulating information to ensure production is accurate and smooth. In this particular case, the customer combines eight subsystems that include power meters, water meters, alarm output, displays, and I/O status to be controlled by several intelligent controllers with Modbus RTU interface. The Modbus TCP protocol is used for this application due to the distance. System Requirements: • Modbus serial to Modbus TCP translation • Multiple slaves/masters support • Automatic Modbus TCP response time detection Read More
Customer Name	Undisclosed Read More
Solution	Moxa's MGate MB3000 series, a serial to Ethernet Modbus gateway, was selected for their system. For this application, PLCs control the boiler system and intelligent controllers are responsible for retrieving information from the boiler and subsystems. When the control server (IPC) needs to acquire data from the boiler, the intelligent controllers with Modbus RTU interface will retrieve data from the boiler. The command is sent in Modbus TCP packet format through the Local Area Network (LAN) and received by the MB3270. The MB3270 would then convert the packet into Modbus RTU messages for the intelligent controller to send to the remote control server via Modbus TCP. Finally, the intelligent controller receives the command from the IPC and relays the data by using Modbus TCP communication. Normally, PLCs and intelligent controllers control and monitor information separately. This unique architecture will ensure fast retrieval of real time data and allows for immediate alert if the primary communication (PLC) is down. Moxa's MGate MB3270 offers high flexibility. Features that benefit boiler control systems are: • Cascading Ethernet ports for easy wiring • Response timeout auto detection to define the suitable timeout value • Redundant power inputs minimize the risk of data loss in the event of power failures. Today, more and more boiler control systems are being equipped with Moxa's MGate MB3000 series Modbus gateways. Product Solutions: MGate MB3170/MGate MB3270 Series 1 and 2-port advanced serial-to-Ethernet Modbus gateways Read More Log in to view content
Data Collected	Alarms For Automated Applications, Power Supply Voltage, Water Meter Readings Read More Log in to view content
Contents

Technology Category

Networks & Connectivity - Gateways

Applicable Industries

Plastics

Applicable Functions

Process Manufacturing

Use Cases

Remote Control

Challenge

Factory automation applications must be equipped to handle and monitor the myriads of information from attached devices. For plastic manufacturing applications, the boiler control system plays a critical role by gathering and regulating information to ensure production is accurate and smooth. In this particular case, the customer combines eight subsystems that include power meters, water meters, alarm output, displays, and I/O status to be controlled by several intelligent controllers with Modbus RTU interface. The Modbus TCP protocol is used for this application due to the distance. System Requirements: • Modbus serial to Modbus TCP translation • Multiple slaves/masters support • Automatic Modbus TCP response time detection

Customer Name

Undisclosed

Solution

Moxa's MGate MB3000 series, a serial to Ethernet Modbus gateway, was selected for their system. For this application, PLCs control the boiler system and intelligent controllers are responsible for retrieving information from the boiler and subsystems. When the control server (IPC) needs to acquire data from the boiler, the intelligent controllers with Modbus RTU interface will retrieve data from the boiler. The command is sent in Modbus TCP packet format through the Local Area Network (LAN) and received by the MB3270. The MB3270 would then convert the packet into Modbus RTU messages for the intelligent controller to send to the remote control server via Modbus TCP. Finally, the intelligent controller receives the command from the IPC and relays the data by using Modbus TCP communication. Normally, PLCs and intelligent controllers control and monitor information separately. This unique architecture will ensure fast retrieval of real time data and allows for immediate alert if the primary communication (PLC) is down. Moxa's MGate MB3270 offers high flexibility. Features that benefit boiler control systems are: • Cascading Ethernet ports for easy wiring • Response timeout auto detection to define the suitable timeout value • Redundant power inputs minimize the risk of data loss in the event of power failures. Today, more and more boiler control systems are being equipped with Moxa's MGate MB3000 series Modbus gateways. Product Solutions: MGate MB3170/MGate MB3270 Series 1 and 2-port advanced serial-to-Ethernet Modbus gateways

Data Collected

Alarms For Automated Applications, Power Supply Voltage, Water Meter Readings

Impact #1	[Efficiency Improvement - Deployment] Advanced functions minimize the effort required for implementing a Modbus architecture
Impact #2	[Cost Reduction - Connectivity] Less Ethernet wiring effort. Cost-effective serial-to-Ethernet Modbus solution that leverages existing utilities and devices.
Impact #3	[Efficiency Improvement - Communication] Warning relay by output. Multiple masters and slaves to ensure smooth data updates

Impact #1

[Efficiency Improvement - Deployment]
Advanced functions minimize the effort required for implementing a Modbus architecture

Impact #2

[Cost Reduction - Connectivity]
Less Ethernet wiring effort. Cost-effective serial-to-Ethernet Modbus solution that leverages existing utilities and devices.

Impact #3

[Efficiency Improvement - Communication]
Warning relay by output. Multiple masters and slaves to ensure smooth data updates

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Overview

Boiler Control System for Plastic Manufacturing Applications

Operational Impact