Ethernet technology in process industrial automation
Industrial Ethernet has long been well-known and widely used in factory automation. However, process automation in the industry has specific requirements, particularly in cases where some processes may involve potentially explosive environments, making Ethernet unsuitable. These specific requirements include intrinsic safety, online configuration, redundant design (for maximum availability), and long cabling (industrial Ethernet cables are limited to 100 meters in length ). When describing Ethernet technology in the process automation industry, it is crucial to differentiate its availability across different zones.
Excom in Danger Zone 2
Turck offers the Excom fieldbus system , which can be installed in Hazard Zone 2. The Excom system uses Ethernet technology and can acquire signals from Hazard Zone 1 or Hazard Zone 0. To plug or unplug the gateway's Ethernet connector during operation, the gateway must be powered off or a hot work permit must be available. All other components (such as power supplies, gateways, or I/O modules) can be replaced during operation without a hot work permit.
Ethernet technology in Hazard Zone 1
From a technical standpoint, using Ethernet in Hazard Zone 1 is more challenging. For interconnected devices, total power must be kept within safe limits. Many automation companies are currently looking to overcome these hurdles and develop intrinsically safe two-wire Ethernet standards, using the same line for communication and power. Future standards typically refer to Advanced Physical Layer ( APL ). However, these developments are not yet suitable for widespread industrial applications in Hazard Zone 1 ( as of March 2020 ). In the future, APL should enable Ethernet connectivity to field devices. However, for cost reasons, even after APL is established, classic 4-20 mA technologies and fieldbus systems will continue to coexist.
Ethernet fieldbus protocol communication in explosion-proof areas
Turck's GEN-3G excom gateway transmits signals from zone 0 to the control system at high data rates.
Turck has released a Zone 2 explosion-proof Ethernet gateway for excom I/O systems , ushering in a new era of digitalization and Industry 4.0 for the process industries. All process data can now be transmitted at high speed to IT systems via parallel data channels for analysis and evaluation, providing a faster and simpler way to achieve condition monitoring and predictive maintenance. The new GEN-3G multi-protocol gateway supports Profinet , Ethernet/IP , and Modbus TCP high-speed Ethernet communication.
The gateway integrates switch functionality, enabling linear topology and ring network communication. In addition to power supply and gateway hardware redundancy, excom also supports S2 redundancy mode to ensure maximum availability. Besides providing standard Ethernet redundancy solutions, excom also offers specialized solutions for non-standard protocols.
Whether using excom in Zone 1 , Zone 2 , or a secure area, users can utilize the same DTM , EDS , or GSDML and operate in the same manner. This significantly reduces training workload and ensures flexibility for professionals across different factory areas. Turck's Cloud components and edge devices (such as the TX700 ) are ideal for accessing and routing parallel process data, with a graphical user interface tailored for industrial applications simplifying the selection of relevant information. The analytics system can be hosted on Turck Cloud or other vendor-provided cloud solutions, or on a local network, supporting Turck's encrypted Kolibri cloud protocol, MQTT , and OPC UA protocols.
