High-availability Ethernet in ATEX Zone 1

Challenge

In lithium-ion battery production, explosive atmospheres occur in the electrolyte filling and coating process stages. At the same time, numerous sensors and actuators must be safely connected in these areas. Traditional point-to-point wiring results in high installation effort and complicates maintenance. In addition, space in control cabinets is extremely limited. Operators therefore require an I/O solution that reduces wiring, ensures high communication reliability, simplifies advanced diagnostics and process optimization and complies with international explosion protection certifications.

Solution

TURCK's excom remote I/O system for ATEX zone 1 transmits the signals of intrinsically safe sensors and actuators from zones 0 and 1 to the higher-level control system via Ethernet. Communication between the non-hazardous and hazardous areas is implemented via fiber-optic cable using TURCK's FOCEN11Ex-2G and FOCEN11-3G media converters — over distances of up to 2500 m. From there, multiple excom stations can be integrated with intrinsic safety via copper cables using the GEN-2G Ethernet gateway and communicate via PROFINET, EtherNet/IP or Modbus TCP.
The user employs the MT08-2G compact module rack with the GEN-2G Ethernet gateway. From there, the data is transmitted via Ethernet to the production line control system. All excom components can be installed in compact enclosures to save space and are certified for use in hazardous areas. Using integrated diagnostic functions, excom provides status and process data. Thanks to multiprotocol support, this data can also be transmitted via parallel communication over the same cable to ensure maximum security of process data communication. excom is considered the most compact I/O system of its kind. No other redundant I/O system for hazardous areas can connect up to 960 signals in a standard control cabinet.