A fully automated 50bbl Brew house is capable of producing 400bbls (12400gal.) of beer per day. One Pentra Micro PLC controls the entire system via: 3 modulating steam valves, 78 air actuated valves, 11 pumps, 4 water modulating valves, an entire grain handling system, 3 gear motors, numerous pressure and temperature transducer inputs, 4 flow meters, 11 empty pipe sensors, and many more devices.
PLC Process Design
Pentra Micro PLC used: (1) FC5A-D12X1E
- Modbus TCPIP Master/Slave to another FC5A-D12X1E for CIP functions
- Ethernet to new 12” HG4G touchscreen
- Modbus RS485 to 11 Hitachi VFDs
- Ethernet to Control Room PC for SCADA operation via IDEC TCPIP protocol
List of Modules attached
- (5) FC4A-J8C1 - A total of 37 analog inputs used
- (2) FC4A-K4A1 - A total of 7 analog outputs used
- FC4A-HPC3 - Modbus RS485 comm. connected to 11 Hitachi VFDs
- Expansion power module
- (4) FC4A-N32B3 - A total of 176 digital inputs used
- (4) FC4A-T32K3 - A total of 186 digital outputs used
Features and Benefits of using the embedded Ethernet MicroSmart Pentra
- Ethernet based interface allowed us to install a standard PC with internet explorer and use the built-in control and monitor features from the 12" HG4G. By NOT having to purchase a third party SCADA program, we saved the customer approx. $25,000.
- Ethernet based connection allowed multiple interactions through only one port (i.e. touchscreen, programming, TCPIP Modbus link to another PLC) thus saving module space for more analog I/O.
- Ethernet based connection allowed for easy remote connection to the PLC and touchscreen.
- Ethernet based connection will be used for easily adding future touchscreens.
- Ethernet based PLC processor was powerful enough to run the entire Brew House using only one MicroSmart Pentra PLC.
Simple diagram of design/system
Picture of actual control panel with IDEC PLC and modules