This application story focuses on addressing the critical need for robust and reliable wireless measurement solutions within large-scale industrial cooling systems. It highlights how wireless instrumentation can overcome the challenges posed by expansive physical layouts and the imperative for seamless data integration with existing Human-Machine Interface (HMI) systems.
- Wireless Data Acquisition: Overcoming physical layout constraints in large facilities through wireless sensor deployment.
- Integrated Monitoring: Measuring both temperature and pressure within water chiller manifolds.
- HMI System Connectivity: Ensuring compatibility and data transfer to industrial control systems.
- Flexible Deployment: Exploring options for both fully wireless and wired-to-wireless sensor configurations.
In a large facility utilizing water chillers and intricate manifold systems for cooling, the precise and continuous monitoring of pressure and temperature is paramount for operational efficiency and predictive maintenance. The sprawling physical layout of such facilities often presents significant challenges for traditional wired sensor installations, including the expense and complexity of extensive cable runs. To address these issues, a customer sought a wireless solution for measuring temperature and pressure at multiple points within their water manifold cooling system. Their objective was to integrate these measurements seamlessly with their existing HMI system, requiring flexible options for both fully wireless pressure and temperature transmitters, or wired end devices connected to wireless transmitters.
The proposed solution centered on the IW Series Wireless Measurement System, which provides a flexible and cost-effective alternative to conventionally wired transducers. For temperature measurement, the IWTT Series Industrial Wireless Temperature Transducer was recommended. This transducer can be configured with either J or K type thermocouples or 3-wire RTD sensors, and in this specific case, a PT100 temperature sensor probe with a 100 mm length and a 1/4 NPT male process connection was identified as suitable. The IWTT Series offers a robust design with a 316 stainless steel probe sheath and an acetal wireless enclosure for excellent media compatibility in demanding applications. For pressure monitoring, the IWPT Series Industrial Wireless Pressure Transducer was proposed, designed to measure gauge pressure, with a specific requirement for a 150 psi gauge range and a 1/4 NPT male process connection. This transducer utilizes a piezo-resistive ceramic sensor housed within a 316 stainless steel body, ensuring compatibility with liquids and gases in harsh environments.
Both the IWTT and IWPT series transmitters operate on a 2.4 GHz frequency and offer user-selectable transmission update rates, including 10-second intervals for extended battery life of up to five years. A key advantage of these wireless devices is their line-of-sight range of up to 500 meters, which significantly reduces the need for expensive cabling in large facilities.
To facilitate communication with the HMI system, two receiver options were considered. The IWR-5 Five Channel Wireless Receiver was initially suggested, capable of pairing with up to five wireless transmitters and providing user-selectable 1-5V or 4-20 mA analog outputs. It also includes a clean contact output for process, low battery, or loss of signal alarm functions. For enhanced integration with the existing HMI, especially if it supports Modbus RTU, the IWR-PORT Wireless to Ethernet or RS-232/485 Gateway was presented as an alternative. This gateway can transfer data from up to 128 wireless nodes onto an Ethernet or RS-232/485 network, making it compatible with standard Modbus TCP/IP or Modbus RTU protocols, which is ideal for industrial automation systems. The IWR-PORT allows for the easy integration of wireless networks into new or existing wired systems without the need for extensive additional cabling, addressing the customer’s need for seamless data transfer to their HMI system. Both receivers offer “plug and play” pairing with the wireless transducers, simplifying installation and setup.
IW Wireless Pressure & Temperature Monitor with Analogue/RS485 Modbus Slave Output Receiver
- Part No: IWPTU-GP150-00, IWTTUP100A, IWR-5, IWR-PORT-485
- Wireless Transmitters: Pressure Sensor, Temperature Sensor Probe – PT100
- Process Connection: 1/4 NPT male
- Pressure Ranges (psi): 150 psi g
- Length of PT100 Probe: 100 mm
- Wireless Receivers: Five channel 1-5V or 4-20 mA output, RS485 serial port with Modbus RTU