IO module replacement advice: Consider legacy connections, Ethernet, peer-to-peer

I/O wiring can be among the most challenging (and perhaps feared) of upgrades. When replacing input/output connections, what are key considerations? Daniel Liu, business development manager, data acquisition and control, Moxa Technologies Inc., offered answers to some key questions.

10/20/2011


The history of I/O wiring can be divided into three phases.

Moxa ioLogik E4200 Modular Ethernet Remote IO adaptor. Courtesy: Moxa TechnologiesIn the first phase when remote I/O products were not available, all I/O contacts needed to homerun all wires back to where the controller was located. As running cables can be costly and troublesome, PLC or controller manufacturers began to use different vendor-defined protocols, or fieldbus networks, to develop remote I/O technology. In this way, less cabling infrastructure was required since only one set of wires (such as Ethernet or serial) was required to homerun to the controller, as compared to multiple wires from each I/O contact in a traditional I/O deployment.

A more recent development in remote I/O technology corresponds to the advent of Ethernet in automation applications. Running a fieldbus protocol over Ethernet makes it more convenient to build just one Ethernet infrastructure and use Ethernet switches to extend the reach of the remote I/O (as compared to serial-to-Ethernet infrastructure). This use of Ethernet infrastructure provides a substantial benefit, reducing cabling costs.

As Ethernet becomes more of a standard in the remote automation space, new I/O installations will need to be integrated with older systems that may still be using serial-based remote I/O technology, or are running hard wiring from the I/O contacts to the I/O controller (an extremely traditional deployment of I/O). To upgrade the older system and reduce cabling infrastructure, one technique is to use TCP/IP, so the operator can enable peer-to-peer communications between two remote I/O connections to replicate the I/O signal over an IP-based network.

For example, Moxa’s ioLogik E1200 series modules are designed to be used as a remote I/O as well as the cable replacement solution. The modules enable the capture of digital and analog signals and then translate those signals into TCP/IP packets. They then send the TCP/IP packet through the network and reproduce the digital and analog signal at the other end.

This gives I/O module replacement a tremendous advantage in that now the I/O signal can run through any type of IP-based network, including wireless. (Despite wireless applications for remote I/O, this technology is still considered premature as IEEE 802.11 technologies used for simple data acquisition applications are considered an alternative to wired remote I/O solutions.) In conclusion, peer-to-peer communication provides the operator with the ability to seamlessly integrate I/O connections to the Ethernet network, thereby saving time and money. Building unnecessary cabling infrastructure becomes a practice of the past.

Moxa provides additional help on cable replacement in remote I/O applications. http://www.moxa.com/Event/Net/2010/Peer-to-Peer_Remote_IO/index.htm 

- Daniel Liu is business development manager, data acquisition and control, Moxa Technologies Inc. Edited by Mark T. Hoske, CFE Media, Control Engineering, www.controleng.com.

www.moxa.com 



Engineers' Choice Awards
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by Control Engineering subscribers.
System Integrator Giants
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
How to Maximize Factory Automation Efficiency with Low Cost Machine Vision
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Wireless Reliability in Harsh Environments
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
October 2018
HMI hardware evolution, Data acquisition strategies, Matching motors and drives, Machine vision advice
September 2018
Optimize controls via cloud software, ladder logic simulation, industrial wireless best practices
August 2018
Augmented reality and virtual reality education, autotuning PID control, cybersecurity advice, educating engineers
Edge Computing
This article collection contains several articles on how today's technologies heap benefits onto an edge-computing architecture such as faster computing, better networking, more memory, smarter analytics, cloud-based intelligence, and lower costs.
Data Center Design
Data centers, data closets, edge and cloud computing, co-location facilities, and similar topics are among the fastest-changing in the industry.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
SIDB

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, progressive cavity pumps
John O. Ayuk, PE, CFSE, PMP, CAP
Automation Engineer; Wood Group
Doug Baker
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Engineers' Choice Awards
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by Control Engineering subscribers.
System Integrator Giants
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
How to Maximize Factory Automation Efficiency with Low Cost Machine Vision
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Wireless Reliability in Harsh Environments
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
October 2018
HMI hardware evolution, Data acquisition strategies, Matching motors and drives, Machine vision advice
September 2018
Optimize controls via cloud software, ladder logic simulation, industrial wireless best practices
August 2018
Augmented reality and virtual reality education, autotuning PID control, cybersecurity advice, educating engineers
Edge Computing
This article collection contains several articles on how today's technologies heap benefits onto an edge-computing architecture such as faster computing, better networking, more memory, smarter analytics, cloud-based intelligence, and lower costs.
Data Center Design
Data centers, data closets, edge and cloud computing, co-location facilities, and similar topics are among the fastest-changing in the industry.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
SIDB

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, progressive cavity pumps
John O. Ayuk, PE, CFSE, PMP, CAP
Automation Engineer; Wood Group
Doug Baker
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Engineers' Choice Awards
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by Control Engineering subscribers.
System Integrator Giants
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
How to Maximize Factory Automation Efficiency with Low Cost Machine Vision
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Wireless Reliability in Harsh Environments
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
October 2018
HMI hardware evolution, Data acquisition strategies, Matching motors and drives, Machine vision advice
September 2018
Optimize controls via cloud software, ladder logic simulation, industrial wireless best practices
August 2018
Augmented reality and virtual reality education, autotuning PID control, cybersecurity advice, educating engineers
Edge Computing
This article collection contains several articles on how today's technologies heap benefits onto an edge-computing architecture such as faster computing, better networking, more memory, smarter analytics, cloud-based intelligence, and lower costs.
Data Center Design
Data centers, data closets, edge and cloud computing, co-location facilities, and similar topics are among the fastest-changing in the industry.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
SIDB

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, progressive cavity pumps
John O. Ayuk, PE, CFSE, PMP, CAP
Automation Engineer; Wood Group
Doug Baker
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me