I have a Process Control Training Skid that was constructed several years ago and I am currently working on connecting it to a CLX PLC for training purposes. The skid includes (2) Foundation Fieldbus instruments - a valve and a flow meter - both of which would be costly to replace. I am exploring alternative options to integrate these two instruments with the CLX system, and I am open to different protocols. I looked into a Prosoft Ethernet IP to FF converter, but the price of $3900 was higher than I anticipated. Since this setup is primarily for training purposes and not high reliability, I am willing to consider any feasible solution. In summary, I am seeking to control 2 Foundation Fieldbus Instruments (1 Valve, 1 Flowmeter) from a Control Logix chassis.
When it comes to Foundation Fieldbus, affordability isn't a quality commonly associated with its components. The limited options available all come with a hefty price tag, which may not sit well with your budget. One potential choice is the Rockwell: Foundation Fieldbus | Allen-Bradley system. Alternatively, you could consider the Prosoft: Foundation™ Fieldbus H1 Master for EtherNet/IP™ and Modbus® TCP by ProSoft Technology, Inc. Personally, I have experience with the Softing Modbus TCP/FF HSE to Foundation Fieldbus H1 Gateway by Softing.
Finding publicly available Foundation Fieldbus (FF) tutorials can be a challenge, as much of the content out there is focused on sales and promotions. If you lack a strong demand for FF instruction, as well as the necessary background and resources (given its complexity and multitude of protocol rules), consider using HART transmitters instead to save on costs and avoid potential issues. When it comes to making changes to FF transmitters like renaming tags, using a Powerpoint presentation along with a Softing FF modem can help navigate the intricate process more effectively.
Danw pointed out the lack of publicly available Fieldbus Foundation (FF) tutorials, with most content being sales or promotional in nature. If there is a clear demand for FF instruction and you have the necessary knowledge and resources (as FF is complex with numerous protocol rules), consider replacing FF transmitters with HART transmitters to save costs and avoid complications. Utilize a 40-slide PowerPoint presentation created for using the Softing FF modem to navigate through the process of changing tag names on FF transmitters. Alternatively, consider selling FF devices on platforms like eBay and replacing them with 4-20mA or HART devices for a more streamlined approach.
Fortunately, we contacted our trusted Instrument Supplier to arrange for the replacement of the boards on the MicroMotion Flow Meter and Valve with Hart / 4-20. Thank you for your valuable feedback.
If cost is a concern, you may want to consider a HART to Modbus converter. These converters can be affordably sourced, likely for a much lower outlay than the Prosoft solution you found. The process behind it is simple; the HART devices would send analog signals to the converter, which would then translate them into the Modbus protocol compatible with your CLX system. It's a generally effective, cost-friendly solution albeit slightly 'old-school'. It doesn't hold up against a direct FF to Ethernet conversion in terms of performance, but for a training setup aiming for learning over high-end performance, it should serve your purpose just fine!
You might want to consider using a HART to Modbus converter. This should give you the functionality you're looking for at a more reasonable cost. Automation Direct offers several affordable options for this. You will then be able to use your ControlLogix PLC to communicate with the converter over Modbus. The converter will essentially act as a bridge, translating between the HART protocol of your current devices and the Modbus protocol your PLC uses. For a training environment, this should provide a good way to integrate your existing instruments without incurring high costs. Plus, it provides an extra layer of learning in dealing with protocol converters.
Have you considered using a Foundation Fieldbus to Modbus TCP gateway instead? They are often more affordable than the Prosoft option and can serve the same purpose for training setups. There are several manufacturers that offer cheaper alternatives, and you might be able to find a used unit. Additionally, it could allow you more flexibility if you decide to incorporate other instruments in the future. Just make sure the gateway you choose supports the functionality you need for both the valve and flowmeter!
Have you considered using a cheaper alternative like a Gateway or Device Server that supports Foundation Fieldbus to Ethernet/IP? Some third-party manufacturers offer more budget-friendly solutions that might be a better fit for training purposes. Additionally, you could look into using a Raspberry Pi or similar microcontroller to act as a bridge; it would require some programming, but it can be a fun project and keep costs lower. Just make sure that whatever solution you choose, it’s compatible with your existing setup!
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