Category: Industry trends

The power supplies and power distribution, if incorrectly designed, are a possible electrical or fire safety hazard and can contribute to common cause failure. It is therefore necessary to:

• Establish the power philosophy, specific earthing philosophy, power requirements, and the separation requirements where items of equipment are separately supplied, for example system internal supplies and field loop supplies.

• Make sure that the chosen Power Supply Units (PSUs) are compatible with the powerfeeds supplied. Alternatively, measures must be put in place to make sure that the power feeds stay within the specifications of the PSUs.

• Define the power distribution requirements, together with the protective philosophy for each distribution; for example, current limited at source or protective devices. Where protective devices are used, it is important to find out that sufficient current will be available to make sure their protective action and the protective device can break the maximum prospective fault current.

• Make sure that the power supplies are sufficient to meet the system load and for any foreseeable load requirements and load transients

• Make sure that the power supplies have a minimum hold up time of 10 ms.

• Make sure that the power distribution cabling is sized to allow the maximum prospective fault currents and tolerable voltage losses. This is specifically important where floating supplies are employed and other power sources can cause high prospective fault currents if multiple earth faults occur.

Controller Power Supply Requirements

A controller requires the following power supply sources:

• A dual redundant power supply of + 24 Vdc with an operating range of 18 Vdc to 32 Vdc. The AADvance controller is designed to accept supply transient and interference according to IEC 61131 part 2.

An over current fault in the controller must not cause the system to lose power. Consequently, the power sources must be able to supply the peak current to open any over current protection devices (such as fuses) without failing.

The power supply protection of the controlleris in the modules, the power distribution arrangement must have a circuit breaker on the input side of each power source. The controller is designed to be resistant to a reverse polarity connection without permanent damage.

The power sources must come from a commercially available industrial uninterruptible power supply (UPS) system. An applicable UPS must have the capacity sufficient to satisfy the entire system load (including field devices and the controller) and an applicable contingency allowance for projected future expansion.

Power Arrangements for Field Devices

Output modules use an external source of power for field devices. This may be the power source used forthe controller or a separate power source.

• For digital and analogue outputs a field power supply of +24 Vdc within a range of 18-32 Vdc is required.

Recommended field circuits are given for each type of I/O module later in the section “Connecting Field Wiring”.

Power Distribution Protection

The power distribution circuit for each field input and for each output module must be protected, externally to the controller. Rockwell Automation recommend that power distribution must meet national and local panel wiring protection standards.

Digital Output Field Power

Special fusing arrangements are required for Digital Output field supplies for UL, ATEX and IECEx approved installations, (see topic on field loops for Digital Output Modules).

Estimating Power Consumption

To estimate the power supply requirements (power supply sizing) you need to know the power consumption of all the modules. Use the following table to estimate the system power consumption.
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The S600+ installation must conform to all applicable local codes and regulations. All installation procedures should be in accordance with normal practices of good workmanship. Although the S600+ shipped to you may not include all of the hardware options described in this manual, the procedure for the basic installation of the unit remains the same.

Note: We strongly recommend you familiarize yourself with the procedures described in this chapter before you begin to install the S600+.

The S600+ uses a modular design that provides maximum flexibility and ease of installation. The basic panel-mounted version consists of three major components:

Fabricated metal case, complete with pre-installed PSU/backplane and four card slots for the modules (a dedicated CPU slot and three I/O slots).

Removable front panel comprising the LCD display and keypad assembly.

Plug-in modules. A CPU module and one I/O module are supplied for a basic configuration; two blank plates are supplied to cover the unused slots.

Note: User-supplied tools to assist in the installation process may include a Phillips screwdriver, a regular screwdriver, a small adjustable spanner wrench, and a 2.5mm Allen key.

Environmental Considerations

The S600+ panel mounted flow computer is designed for use within the control room. Place it in a position that provides ease of use, comfort, and safety for operators and maintenance personnel. The optimum height for viewing and using the display and keypad is at operator eye level.

Required Tools for Installation

Before you attempt to install the S600+, ensure that you have the following tools:

Small flat-blade screwdriver suitable for the slot-headed captive screws on the rear of the case that secure each plug-in board into the case.

5.5 mm (5 BA) hex or small adjustable wrench for the front panel bosses.

2.5 mm Allen key suitable for the hex cap screw on the front face of the front panel that secures the front panel molding to the case.

Installing the S600+

Refer to the following procedures for installing the various S600+ components, including the front panel, panel-mounted unit, and modules.

Unpacking the S600+

Unpack the S600+ carefully and inspect parts for visual damage.

Note: Do not discard packaging material until after you have identified all pieces of the shipment and you are confident that all parts are working correctly.

Removing the Front Panel

To begin the mounting process, remove the front panel from the S600+:

Ensure power has been removed from the S600+.

Using a 2.5 mm Allen key, remove the hex cap screw from the bottom centre of the front panel (refer to Figure 2-2).

Carefully slide the front panel up 4 mm (0.15 in) to allow it to clear the retaining groove at the top of the case, and then allow the panel to come forward to clear the panel case completely (refer to Figure 2-3).

Disconnect the ribbon cable from the back of the front panel at the blue connector (refer to Figure 2-4). Observe the orientation of the connector with its mating keyway. You must correctly re-insert the ribbon cable at the end of the installation process.

Remove the top and bottom bosses from the unit housing, using a 5.5 mm (5 BA) hex wrench.

Installing the Panel-Mounted Unit

After removing the front panel, install the panel-mounted unit:

Keeping environmental considerations in mind, construct the framework of the cubicle to support the operating panel.

Note: A standard 483 mm (19 in) rack that is 311 mm (12.25 in) high can accommodate up to four S600+s provided you support the rear of the case.

Refer to Figure 2-6 and Table 2-1 for position details for two 7 mm (0.276 in) holes and a cutout. The panel cutout should be rectangular for each S600+. Allow a tolerance of ± 3 mm (0.12 in) on each axis.

Note: The S600+ fits into existing S500 and 869 flow computer panel cutouts.

Place the front of the case against the rear of the prepared cutout.

Re-install the top and bottom bosses and tighten with a 5.5 mm (5 BA) hex wrench.

Once you have fitted the rear support, use a self-tapping screw to secure the case to the rear support. The maximum depth of the screw inside the case should be 3 mm (0.12 in)

Reinstalling the Front Panel

Re-installing the front panel is the final stage of the installation process:

Connect the ribbon cable to the front panel.

Place the top of the front panel over the retaining groove on the top boss and slide the front panel downwards.

Secure the front panel by placing the hex cap screw into its recess in the bottom centre of the front panel.

Using a 2.5 mm Allen key, tighten the screw finger-tight. Turn an additional 180 degrees clockwise to complete the installation.

Installing and Removing Modules

The S600+ ships with the CPU and I/O modules already installed. Follow this procedure if you need to remove the modules for maintenance or upgrade purposes.

The CPU module is located at the left-most rear slot of the case. You can insert I/O modules in the remaining slots or leave them empty. Cover any empty slots with the blank cover plates.

The FEM100 module increases the number of 200 Series (or equivalent) FBMs supported for the FCP270 modules to up to 128 FBMs for typical control usage. The FEM100 provides four Expanded Fieldbus ports, each of which is capable of communicating with up to thirty-two FBMs. This is illustrated in Figure 3.

The FCP270 requires I/A Series software v8.3-v8.8 or Control Core Services v9.0 or later to support the FEM100 module.

The FCP270 baseplate may connect to a Two-Slot Expansion Baseplate which accommodates a single or pair of FEM100s. A Four-Slot Expansion Baseplate is also provided which can accommodate up to two fault-tolerant FCP270s and a single or pair of FEM100s.

For a description of these baseplates, refer to PSS 21H-2W6 B4.

A pair of FEM100 modules provides redundancy for the Extended Fieldbuses. When both modules are active, the FCP270 sends and receives communications across both A and B buses. In the case of a FEM100 module failure, the FCP270 switches all traffic to the bus with the available FEM100 module until the failed module is replaced.

FBI200/FBI100 FIELDBUS ISOLATOR/FILTER

The FBI200 and FBI100 Fieldbus Isolator/Filters are designed to filter and isolate 2 Mbps communications from an FCP270 to the Fieldbus Isolator (FBI) which requires 268 Kbps signals for 100 Series FBMs and similar Migration modules. This enables the FCP270 to communicate with both 200 Series FBMs (over 2 Mbps signals) and 100 Series FBMs (over 268 Kbps signals) simultaneously when the FBI100 is installed as specified.

The FBI100 also extends the length of the 268 Kbps module Fieldbus from the FCP270 to 100 Series FBMs and similar competitive migration modules up to 1830 m (6000 ft) over a twinaxial Fieldbus cable. See Figure 2 on page 4.

For more information on the FBI200, refer to PSS 21H-2Y18 B4.

For more information on the FBI100, refer to PSS 21H-2Y16 B4.

ON-LINE IMAGE UPDATE

For fault-tolerant FCP270 modules, on-line image update replaces the executable image (operating system) of a running FCP270 with a newer image without having to shut down the equipment being controlled by the FCP270. New product enhancements can be brought on-line in 1.5 seconds for heavily loaded controllers; less for lightly loaded controllers.

Because the FCP270 contains its executable image in internal flash memory, and has sufficient RAM to hold a new executable image at the same time, online image updates are now much easier to perform.

TIME SYNCHRONIZATION, SOE, TDRA

The Foxboro Evo system supports time synchronization using either an externally maintained optional source of Universal Coordinated Time (UTC) from GPS satellites or an internal source using proprietary software. Controllers that receive time updates via the external time source synchronize their FBMs to 1 ms. For more information on time synchronization, refer to PSS 21S-1C2 B3. Time stamping is used for alarm messages, values sent to the historian, and the new Sequence Of Events (SOE) and Transient Data Recorder and Analyzer (TDRA) features. SOE data are discrete points that are time stamped at the FBM, optionally to 1 ms, and sent to the workstation on a change basis. TDRA data are analog points that are time stamped at the FBM and sent to the workstation every 10 ms. These new features are supported by client software in the workstation. For information on this new software, refer to PSS 21S-2B9 B4 and PSS 21S-2B10 B4.

SOFTWARE FEATURES

The FCP270 performs regulatory, logic, timing, and sequential control, as well as data acquisition, alarm detection, and alarm notification. Process variables are controlled using time-proven algorithms (mathematical computations performing specific functions). The algorithms are contained in functional control blocks, which on-site process engineers configure to implement the desired control strategies. The versatility of the algorithms, coupled with the variety of FBMs available, provides control capabilities suited to a broad range of process applications. Control strategies ranging from simple feedback and cascade loops to highly sophisticated feedforward, nonlinear, and complex characterization control schemes are readily implemented.

The FCP270 also supports the following features:

Infrared communications with the controller enables you to set and read the controller letterbug via the Letterbug Configurator

Alarm enhancements to function blocks: re-alarming on changes to alarm priority, re-alarming based upon a configurable time delay deadband, and alarm suppression based upon time

Optional UTC external time synchronization

Improved controller performance.

Optional self-hosting mode (I/A Series software v8.4-v8.8 or Control Core Services v9.0 or later) allows the FCP270 to start up and run, executing its configured control scheme using the checkpoint file stored in flash memory. This allows the FCP270 to boot itself with a valid control database even if its host workstation is not present.
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The Field Control Processor 270 is a distributed, optionally fault-tolerant, field-mounted controller that performs process control and alarming functions according to a user-defined control strategy.

FEATURES

Performs regulatory, logic, timing, and sequential control together with connected Fieldbus Modules (FBMs)

Performs data acquisition and alarm detection and notification

Supports up to 32 200 Series FBMs – referring to both Compact or standard types

Supports up to 128 200 Series FBMs (Compact or standard) with a Fieldbus Expansion Module 100 (FEM100)

Supports up to 64 of the 100 Series FBMs

No Fieldbus Communication Module is required

Connects to The MESH control network via standard fiber optic 100 Mbps Ethernet

Uses a rugged, die cast aluminum housing for mounting in a non-vented field enclosure

Can operate in Class G3 harsh environments

Is CE certified for field mounting in enclosures

Supports both the 2 Mbps or 268 Kbps HDLC fieldbuses simultaneously with the FBI200 or FBI100, allowing connections to both 200 Series and 100 Series FBMs (affects the total number of each type of FBM supported).

Offers unique, patented, fault-tolerant operation using two control modules to greatly improve reliability relative to other process controllers

Uses versatile control algorithms and a wide variety of FBMs to provide control capabilities for a broad range of process applications

Supports time synchronization using optional external time from GPS satellites

Offers on-line image update of a fault-tolerant FCP270 without shutting down the process

Uses soft letterbugs configurable via the I/A Series® system Letterbug Configurator running on a Pocket PC

Supports self-hosting mode with I/A Series software v8.4-v8.8 or Foxboro Evo™ Control Core Services v9.0 or later

OVERVIEW

The Field Control Processor 270 (FCP270) is a distributed, optionally fault-tolerant, field-mounted controller module. The FCP270 performs regulatory, logic, timing, and sequential control together with connected Fieldbus Modules. It also performs data acquisition and alarm detection and notification. The FCP270 connects to The MESH control network via standard fiber optic 100 Mbps Ethernet.

The fault-tolerant version of the FCP270 consists of two processor modules. These modules install in adjacent FCP270 slots in a supported FCP270 baseplate for high speed communication between the modules (see Figure 1).

REMOTE MOUNTING

The FCP270 flattens and simplifies the Foxboro Evo Process Automation System architecture, which only requires field enclosures plus workstations and Ethernet switches. For more information on The MESH control network architecture, refer to PSS 21H-7C2 B3.

The field-mounted FCP270 is an integral part of the highly-distributed control network where controllers are closely aligned to specific process units mounted in close proximity to their I/O and the actual equipment being controlled. Coordination between process units takes place via a fiber optic 100 Mbps Ethernet network.

The FCP270 is packaged in a rugged, die cast aluminum housing that does not require venting due to its efficient design. The FCP270 is CE certified, and it can be mounted without expensive special cabinets to prevent electronic emissions. The FCP270 can be mounted in Class G3 harsh environments.

Elon Musk said Thursday he would send Starlink satellite internet terminals to the Federal Aviation Administration and said current technology poses a risk to air travel safety, but did not provide evidence.

The billionaire and senior adviser to President Donald Trump, who is charged with cutting costs across the federal government, made the comments on his social media platform X.

Executives from major airlines told CNBC on Thursday that they do not believe the FAA’s technology poses a risk to air travel safety.

The FAA, which oversees Musk’s company SpaceX, did not immediately comment but said earlier this week that the company has been testing Starlink technology in Atlantic City, New Jersey, and Alaska. The White House referred a request for comment to the FAA.

The FAA said Monday that it has been considering using Starlink to improve reliability in remote areas, including Alaska, “since the last administration.” “This week, the FAA is testing one terminal at its Atlantic City facility and two terminals at non-safety-critical locations in Alaska.”

The Washington Post reported on Wednesday that the FAA is about to cancel its contract with Verizon for new communications technology for air traffic control and transfer it to Musk’s Starlink.

“Verizon’s air traffic control communications system is rapidly failing,” Musk said Thursday on X. Verizon said in a statement that “the FAA system currently in use is operated by L3Harris, not Verizon.” He later corrected himself to say that L3Harris was responsible for the “rapidly failing” system.

L3Harris did not immediately respond to a request for comment.

Verizon said it is working on replacing old air traffic control technology.

“Our company is building next-generation systems for the FAA to support the agency’s mission of enabling safe and reliable air travel,” Verizon said in a statement. “We are embarking on a multi-year contract to replace an outdated legacy system. Our team has been working with the FAA’s technical team and our solution is ready to deploy. We will continue to work with the FAA to achieve its modernization goals.”

Musk did not immediately respond to a request for comment.

Some Democratic lawmakers have expressed concerns about Musk’s role in the Trump administration and the possibility that he could provide technology to one of Trump’s regulators.

“While I support efforts to modernize our air traffic control system and improve aviation safety, this decision raises concerns about conflicts of interest given Elon Musk’s dual role as CEO of SpaceX and his extensive role in the Trump administration,” Sen. Ed Markey, D-Mass., said in a letter to FAA Acting Administrator Chris Rocheleau on Wednesday.

Others have also sounded the alarm after the Trump administration fired hundreds of FAA employees, which did not include air traffic controllers.

“At a minimum, we need to know why the sudden layoffs were necessary, what types of work these employees were doing, and what analysis, if any, the FAA conducted to ensure this would not adversely affect safety, increase flight delays, or harm FAA operations,” Sen. Tammy Duckworth, D-Ill., wrote to Rocheleau on Feb. 19.

The FAA said it has retained “individuals who perform safety-critical functions. The FAA does not comment on ongoing certification work.”

For years, airlines have been pushing to modernize air traffic. Airlines have long complained that old systems could not meet industry needs, causing flight delays and losses for both passengers and airlines. After the pandemic, demand for air travel hit a record high.

“Airlines have made significant changes and investments in technology, operations, products and people. Government needs to do the same in an organized and timely manner,” Airlines for America, which represents major U.S. airlines, said Thursday.

Musk’s comments about aviation safety failures, which he did not provide any evidence of, come just last month when an American Airlines regional jet collided with an Army Black Hawk helicopter, killing all 67 passengers and crew on board. The accident ended an unprecedented period of air travel safety in the United States, the first fatal passenger plane crash in the United States since 2009 and the deadliest accident since 2001.

Last week, more than a dozen aviation industry groups and unions urged lawmakers to approve “emergency funds” for air traffic control modernization and staffing.
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Germany’s election results brought a glimmer of optimism to sluggish markets at the start of the week, but questions remain over whether the new government can deliver on its promises to increase public spending and revive the economy.

Frankfurt’s DAX rose 0.6% on Monday, outpacing a flat FTSE 100 in the UK and a 0.78% drop in France’s CAC 40, as the euro edged higher against the dollar and sterling, and German borrowing costs barely changed.

Sunday’s election results showed a win for the conservative coalition of the Christian Democratic Union (CDU) and the Christian Social Union (CSU). This means that CDU-CSU candidate Friedrich Merz will almost certainly take over as the next chancellor. Merz is a center-right pro-business politician who currently sits on the boards of EY Germany and Deutsche Börse.

However, some uncertainty remains, with a period of coalition negotiations ahead and the need for support from smaller parties to implement promised policies, including a reform of Germany’s controversial “debt brake” rules.

“I think what the market is seeing now is some kind of stability, at least we know who won the election, we know who claimed victory, and then we know who the coalition will be centered around,” Michael Field, chief equity strategist at Morningstar, told CNBC’s “Squawk Box Europe” on Monday. “So I think the market is viewing this as a huge positive.”

A worse market outcome could result in the CDU not being able to reach the level needed to form a coalition, triggering “months of chaos, scrambling and uncertainty about the business outlook,” Field said.

The outcome is good for the German economy because a two-party “grand coalition” between the Conservatives and the Social Democrats (SPD) now looks possible, a scenario that would speed up decision-making, Danske Bank analysts said in a note.

Whether it’s a two- or three-party coalition and bringing in smaller parties like the Greens — Merz has ruled out governing with the second-place far-right Alternative for Germany — the major parties are aligned on policies like lower energy prices and more infrastructure investment, which would “have a positive impact on business,” Field of Morningstar told CNBC.

Field said the move could provide a boost to sectors such as Germany’s auto industry, a once-mighty industry that has been hit by competition from Chinese electric vehicles, weak domestic demand, U.S. tariff threats and regulation.

“The industry has been hit hard… Our position is that it doesn’t take a lot to turn that around and move it a little bit in a positive direction, and the new government has the power to really lower energy prices and try to make the economy more competitive, and any concessions could really give the industry a much-needed boost right now,” Field said.

The easily overlooked utilities sector is another area that could benefit if the government removes policies such as energy price caps and consumer energy taxes that limit market returns, Field went on to say.

The government needs to develop a long-term agenda to restructure Germany over the next five years, Siemens Energy Chairman Joe Kaiser told CNBC on Monday. That agenda needs to focus on the economy, infrastructure, energy, education, innovation, restructuring the pension system and “taking back control of government and government reform.”

Meanwhile, Arnd Franz, CEO of auto parts maker Mahle, told CNBC that the manufacturing sector needs urgent action on taxes, energy costs and labor market flexibility.

In a note on Monday, Citi analysts stressed that “the post-election policy landscape will depend on the shape of the yet-to-be-formed coalition government.”

They highlighted the potential market impact of smaller parties and said the Greens joining the coalition would be a positive for construction companies that produce heating and cooling equipment, as it would reduce the likelihood of removing subsidies and mandates for heat pump retrofits.

The Citi analysts also said they see “limited medium-term risks to Germany’s onshore wind auction system,” citing the Christian Democratic Union’s platform as arguing that now is the time to “develop the grid, storage facilities and all renewable energy sources.”

“This seems to imply that no major measures will be taken to hinder wind power development,” Citi said, supporting stocks such as Nordex and Vestas, they wrote.

However, key issues that remain for the market to watch include whether the government can get the economy back to growth, rebuild weak business and consumer confidence, and increase fiscal spending by removing constitutional provisions that limit the amount of government debt. The latter point has become a wider focus in recent weeks as European countries discuss increasing defence spending in response to the Russia-Ukraine war and tensions with the US

“The key result from a market perspective is that … the three major establishment parties (Union/CSU, SPD and Greens) did not secure the two-thirds majority needed to amend the constitution,” Rabobank’s economic research team said on Monday.

Therefore, there is no clear path to passing reforms, with the AfD opposing the removal of the debt brake, while the Left is open to it but at odds with the SPD and opposes arming Ukraine.

“Most importantly, yesterday’s election results do not provide a clear path to amending the constitution to allow for a significant shift in government spending,” Rabobank said.

In the absence of a major fiscal shift, the outlook for growth in Germany and the surrounding region “remains very bleak,” they added.
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Beckhoff has developed a TwinCAT Chat client for the TwinCAT XAE development environment, which makes it easy to use large language models (LLMs) such as ChatGPT from OpenAI during the development of TwinCAT projects to improve the programming efficiency of control programs. It also offers optimization potential for direct support.

Large language models (LLMs) are neural networks that have been trained on a large amount of text. In recent years, large language models have been increasingly used in the field of natural language processing, including chatbots and machine translation.

The TwinCAT Chat client automates programming in an AI-supported manner, such as creating or adding function block code, and even refactoring optimized code and writing documentation. The client is implemented in TwinCAT XAE, connects to the respective Large Language Model (LLM) cloud (e.g. ChatGPT is based on Microsoft’s AzureTM), provides a user interface, and communicates with the PLC development environment via the Automation Interface. This is possible via the corresponding chat window in Visual Studio, while the functionality of the LLM has been optimized especially for TwinCAT 3 users, i.e. it has been extensively supplemented with TwinCAT-specific content.

About Beckhoff

Beckhoff is a German company focusing on new automation technologies. It was founded in 1980 and is headquartered in Weil, Germany. As a global driver of automation technology, Beckhoff has defined many standards in the field of automation and is the setter and promoter of international standards. The company’s industrial PCs, fieldbus modules, drive products and TwinCAT automation software constitute a complete and mutually compatible control system that can provide open automation systems and complete solutions for various industrial control fields. After 40 years of development and hard work, Beckhoff has established more than 30 branches around the world, and with global partners, its business covers more than 70 countries and regions.

Beckhoff entered the Chinese market in 1997. Its China headquarters is located in Shanghai North High-tech Industrial Park. It currently has 300 employees and offices in 30 large and medium-sized cities in China. Innovative products and solutions are widely used in many fields such as wind power generation, semiconductors, photovoltaic solar energy, electronic manufacturing, metal processing, packaging machinery, printing machinery, plastic processing, tire processing, wood processing, glass machinery, logistics and transportation, and building automation.

The EtherCAT real-time industrial Ethernet that the company has vigorously promoted became China’s national recommended standard in 2014 and has been included in the “Guidelines for the Construction of the National Intelligent Manufacturing Standard System” of the Ministry of Industry and Information Technology. As a technology-driven company, Beckhoff has always focused on seeking breakthroughs and innovations in technology and enjoys a reputation as an “innovation engine” in the industry. Beckhoff’s PC-based control technology has good openness. It supports all mainstream industrial communication protocols and perfectly integrates IT technology, the Internet and automation technology, laying a solid technical foundation for the realization of Industry 4.0 and intelligent manufacturing.
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3BHE057901R0101  PCD235
3BHE039724R0C3D PPD513AOC-100440
PCD235C101  3BHE057901R0101
GFD563A102 3BHE046836R0102
GFD233A101 3BHE022294R0101
GFD563A101 3BHE046836R0101
GFD563A102  3BHE046836R0102
GF D563  3BHE046836R010
PPD512 A10-15000 3BHE040375R1023
More……