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PLC Integration Overview

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Integration Overview

The Dilution Control System connects to the PLC/controller that operates the dilution valves. The PLC handles the low-level valve control while the Dilution Control System provides the high-level profile control logic.

Dilution Control System
Profile control, setpoint calculation
Setpoints ↓ ↑ Feedbacks
PLC / Controller
Valve control, safety interlocks
Analog Out ↓ ↑ Analog In
Dilution Valves
Flow control per zone

Supported PLCs

The system supports integration with the following PLC platforms:

Modbus TCP

Generic protocol for any Modbus-compatible PLC or controller

View Guide →

Siemens S7

S7-1200, S7-1500, S7-300/400 via S7-TCP protocol

View Guide →

Beckhoff

EK9000 coupler, TwinCAT via ADS protocol

View Guide →

Festo CPX

CPX-FB36 with Modbus TCP, optimized timing

View Guide →

Communication Protocols

Protocol Port Used For Features
Modbus TCP 502 Generic PLCs, Festo, Beckhoff EK9000 Universal, simple, reliable
S7-TCP (ISO-on-TCP) 102 Siemens S7 PLCs Native Siemens protocol, high performance
ADS (TwinCAT) 48898 Beckhoff TwinCAT Symbol-based access, diagnostics

Data Exchange

The following data is exchanged between the Dilution Control System and the PLC:

To PLC (Outputs)

Data Type Description
Zone Setpoints Float Array Target position for each valve (0-100%)
Zone Mode Int Array Control mode per zone (Auto/Manual/Local)
Global Mode Int System-wide control mode
Heartbeat Int Communication watchdog

From PLC (Inputs)

Data Type Description
Zone Feedbacks Float Array Actual position of each valve (0-100%)
Zone Status Int Array Status/error flags per zone
System Status Int Overall system status

PLC Selection Guide

Choose a PLC based on your requirements:

Use Modbus TCP When:

  • You have an existing Modbus-compatible PLC
  • You want vendor-independent solution
  • You're using Festo valve terminals
  • Budget is a primary concern

Use Siemens S7 When:

  • Site standard is Siemens PLCs
  • Integration with existing Siemens infrastructure
  • You need advanced diagnostics
  • High-performance requirements

Use Beckhoff When:

  • EtherCAT I/O is already installed
  • TwinCAT-based automation
  • Need for PC-based control flexibility
  • High zone counts with EK9000
Recommendation

For new installations, Modbus TCP provides the best balance of compatibility, simplicity, and cost. It works with most PLCs and valve terminals.