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Ask the I/O Experts
Question: I need a dual-input/single-output converter that accepts two 4-20mA PLC analog output signals and allows either signal to be selected as the converter output by a digital PLC output. This is for a redundant PLC I/O application - if either PLC output fails the other output is selected as the 'duty' control signal to the control valve.
Solution #1: Automatic control/selection
1pc, Model 892M-0500, Math Module with 2AI's and 1 AO.
This product can accept two 4-20mA inputs and provide one 4-20mA output. You could enter a simple "excel spreadsheet type equation" that automatically selects the higher of the two inputs. So, if one is lower or drops down to 0mA in case of failure, the other channel will kick in automatically. Example Equation: Output=Max(A,B,4) {with this equation, you'll clamp the lowest output of the 892M to 4mA)
1pc, Model 800C-SIP, Software Configuration Kit for 892M
Solution #2: Digital control/selection
Same as above except you use a SPST N.C. mechanical relay output from the backup PLC wired directly across the "B" channel Input to 892M (ie; in parallel). This will always "short out" the current input to channel B causing the 892M CH B reading to be 0mA. In the event of a failure on ch A (ie; 0mA), channel B relay could be programmed to "open" and allow ch B to begin reading the 4-20mA signal. Same equation as above will work for this solution. Note, you will probably see a very brief "transitional" glitch with this solution (ie; 500mS or less typically).
Solution #3: Go Ethernet Modbus TCP/IP or Ethernet IP if Allen Bradley
1pc, Model 972EN-4004 (MB TCP/IP) or 972EN-6004 (Ethernet IP): 4ch AO-I module, Ethernet. Acromag's Ethernet Modules support "multi-master" communications (ie; up to 10masters typically). So, you could have this 4ch AO-I module being driven from either of 2 PLC masters. You need the interlock logic between the PLC's to determine who takes control of the module (ie;token ring passing, simple relay command between plc's, or thru the comm. Port communications)
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