The global use of production systems and remote maintenance require flexibility and direct external access to the systems. Whereas in the past the technician sometimes had to travel halfway around the world to rectify faults on a system, today systems located abroad can often be accessed at the click of a mouse. On the one hand, this requires the necessary equipment to enable remote access and, on the other, the consideration of high security requirements. Equally important is the early detection of undesirable developments in plant operation. A key aspect of this is the recording and processing of measured values. Measured values also play an important role in quality control. However, the large amount of information results in a higher volume of data on the bus systems. As this is not desirable, measured values are often transferred directly to the cloud bypassing the control bus. Communication types such as OPC UA are suitable for this.

Remote access to the 24 V (DC) power distribution system

At the heart of every system is the 24 V (DC) fuse and power distribution. The control voltage supplies a large number of sensors, pumps and valves that measure the values for process control and then control the process with the connected actuators. The 24 V (DC) voltage level is also used to supply the control systems. If there is a power failure, the control system is no longer supplied, which would result in the system being switched off and the production process being interrupted in an uncontrolled manner. To prevent this, intelligent protection of the connected loads is required. The 'ControlPlex' system from E-T-A, for example, is ideal for this purpose. It consists of the 'CPC20' bus controller for communication with the higher-level systems, the 'Modul 18plus' power distribution system and the 'ESX60D' electronic circuit breaker for selective protection of the connected loads.

Transparency via bus controller

Intelligent power distribution systems are finding their way into industrial production facilities. A modular design increases flexibility.

© E-T-A

The bus controller is the 'brain' of the 'ControlPlex' system and acts as an interface to the various control systems and to the cloud. It is connected directly to the power distribution system, to which the electronic circuit breakers are plugged. In the standard configuration, 16 connection modules can be connected to the bus controller. A two-channel circuit breaker can be plugged into each connection module, so that 32 channels can be protected. The number of connection modules can be doubled with the aid of a transfer module. This means that the bus controller can communicate with up to 64 fuse channels.

The primary communication interface of the device is the connection to the respective bus system. Connection to Profinet and Ethernet IP is currently possible via two RJ45 sockets. The integrated switch ensures simple connection to the bus system. A third socket enables a service laptop to be connected to the integrated web server. This allows users to access all the information and functions of the system and adapt it quickly and easily when commissioning the system or during subsequent operation. This interface can also be used to transfer system data in JSON format. An OPC UA interface is in preparation. It enables status information and measured values to be transferred directly to the cloud. This allows users to compare different systems worldwide and analyze their measured values.

Modular design

By using base systems, users have the option of adding new consumers during system operation without having to switch off the system's power supply. Unlike DIN rail mounting, the control cabinets with the base systems can be pre-wired in the workshop and adapted as required during commissioning or later operation.

The '18plus' power distribution system consists of three components: The power supply module is connected directly to the switching power supply unit. This enables the connection of cables with a cross-section of up to 16 mm². The maximum current of the system is therefore 80 A. The current is distributed to the connected connection modules via busbars. To install the system, the connection modules are connected in series to the power supply module. Each connection module has three push-in terminals for each fused channel, to which the fused load is connected. These three terminals are: the fused load from the circuit breaker, the 0 V and a terminal for the functional earth.

Up to 16 sockets can be connected to the standard system, thus protecting a maximum of 32 loads. This number can be doubled by using a transfer module. The transfer module is connected to the CPC20. In this case, communication takes place via the connected bus line. As with the standard system, power is fed in via the power supply module. This means that a further 32 channels can be fused and supplied with 80 A. The overall system therefore has the option of protecting up to 64 channels.