Replacing Weidmüller and restoring TPEM ↔ Siemens communication
100% remote replacement of an unavailable Weidmüller communication controller with an OWEN PLC210, restoring Modbus RTU/TCP communication between TPEM and Siemens S7-1500.
Task
Since March, communication between two gas-piston generator units, each with its own TPEM control system, and the higher-level Siemens S7-1500 had been disrupted due to a failed Weidmüller communication controller. A direct replacement was not possible because the required hardware and software were unavailable. The task was to develop a modern replacement, restore data exchange and return the installation to operation without rebuilding the existing control system.
Technical data
- OWEN PLC210
- CODESYS V3.5
- Siemens S7-1500
- TPEM
- Modbus RTU
- Modbus TCP
- 2 analog signals
- 543 Siemens register positions
- 141 TPEM parameters
- 71 event and alarm messages
- 100% remote implementation
Work performed
- Analysis of the existing TPEM / Weidmüller / Siemens S7-1500 architecture and source documentation
- Work with German original software and technical documentation; communication in German, Russian and English
- Development of a replacement solution based on OWEN PLC210 and programming in CODESYS V3.5
- Modbus RTU communication with TPEM and Modbus TCP communication with the Siemens S7-1500
- Integration of an additional analog input module and two analog signals
- Preparation of electrical diagrams, connection drawings and dismantling / retrofit instructions
- Preservation of the existing Siemens data structure and implementation of the required data conversion
- Remote support for the customer’s technicians during installation and rewiring
- Verification of 543 Siemens register positions, 141 TPEM parameters and 71 event / alarm messages
Result
- The installation was restored without a complete rebuild of the existing control system
- The unavailable Weidmüller controller was replaced with a modern programmable solution
- TPEM ↔ Siemens S7-1500 communication was restored via Modbus RTU / TCP
- The existing Siemens data structure was preserved
- The entire project was completed 100% remotely with no on-site visit required
- After receiving the complete source documentation, the solution was developed and commissioned in approximately one week
Photos and videos
Huge thanks to a TOP-CLASS SPECIALIST!!! He solved the problem very quickly and competently, although the service team could not solve it!!! He was able to understand even equipment he had never worked with before!!! I recommend this specialist to everyone!!!