How we connect PLCs, screens, drives, analysers and remote stations into one system, using the networks that suit each installation.
An installation contains devices from different manufacturers and different eras. The communication network is what turns them into one system, so the PLC and SCADA can see and control everything from one point.
Instead of one cable per signal, one network line carries data from many devices, at lower cost and with fewer points of failure.
Besides status, the network carries measurements, settings and diagnostics from every device, which help with maintenance.
New devices are added to the same network, without redoing the installation from scratch.
At each level the network that suits its needs is used: speed and many devices at the control level, simple serial networks for existing instruments, wireless links for distant sites.
Fast and with many devices. It suits connecting PLCs, screens, remote I/O and SCADA. See also the SIMATIC example.
Many instruments, such as analysers, drives and controllers, still speak Modbus RTU or PROFIBUS and are integrated without replacement.
Pump stations and tanks are connected with 4G/5G or a radio link. See telemetry.
The choice is made per project, depending on the equipment already there and how the installation will grow.
| Network | Medium | Where it is used | Note |
|---|---|---|---|
| PROFINET / Industrial Ethernet | Ethernet, fibre | PLCs, remote I/O, screens, drives, SCADA | Main control network in new installations |
| PROFIBUS DP | RS485 | Existing installations and devices | Older network that is often integrated in extensions |
| Modbus RTU | RS485 | Analysers, drives, meters, refrigeration controllers | Simple and widespread across instruments from different manufacturers |
| Modbus TCP | Ethernet | The same instruments, on an Ethernet network | Often through a gateway from Modbus RTU |
| OPC UA | Ethernet | Connecting PLCs to SCADA, MES and IT systems | Manufacturer-independent, with security in the protocol itself |
| Wireless links | 4G, 5G, radio link | Remote stations and water networks | Require a coverage check, see telemetry |
We see which devices exist, which protocol they speak and how far apart they are, so the right network is chosen per location.
Line, star or ring with a redundant path, depending on how critical continuous operation is.
An IP address plan and separation of the control network from the office network, for security and stability.
We test communication with every device and hand over a network diagram and an address list, so a fault is easy to find.
The solution is chosen per project. The network and protocols are chosen depending on the equipment and needs of each installation.
Media, capabilities and limits are indicative and confirmed per project. Protocol and product names (e.g. PROFINET, PROFIBUS, Modbus, OPC UA) belong to their owners. A note by KP AUTOMATION.
Tell us what equipment you have and we will propose the right network.