Remote Water Flow Monitoring: Achieving Precision in Water Resource Management
Using ICP DAS M-7000 Series Analog Input Modules, water pressure data can be collected, while the tM Series Digital Input Modules receive signals from ultrasonic flow meters. Water pressure, flow rate, and water meter data are wirelessly transmitted via the ZT Series ZigBee Converters. Finally, the data is consolidated by the MDC Series Modbus Data Concentrators in each area and sent back to the AVEVA Edge SCADA in the central control room via Ethernet, enabling management personnel to accurately monitor water consumption across the facility and effectively implement water resource management.
Business Strategies Amid Rising Water Costs
With climate change and rising supply costs, governments worldwide have been increasing water rates. For instance, in February 2023, Taiwan’s Water Resources Agency under the Ministry of Economic Affairs implemented a new water consumption fee for high-usage consumers exceeding 9,000 cubic meters per month during dry seasons, imposing an additional charge of NT$3 per cubic meter for excess usage. As a result, businesses must take proactive measures to strengthen water resource management.
In this case, the client is a high-water-consumption panel manufacturer specializing in the production of thin-film-transistor liquid-crystal displays (TFT LCDs), LCD modules, and touch panel modules. Previously, the factory relied on manual data collection from water meters and flow meters. However, since these devices were scattered throughout the facility, manual inspections were not only time-consuming but also lacked real-time updates and carried a risk of transcription errors. Therefore, the client aimed to implement an automated meter reading system without modifying existing equipment, ensuring real-time and accurate data monitoring with minimal labor and time investment.
After careful evaluation, ICP DAS’s professional team adopts a wireless approach to avoid the disruptive impact of physical wiring, which could damage existing equipment and cause partial production line shutdowns. This case study demonstrates how ICP DAS’s automated water resource monitoring solution enables remote and unified management of water pressure gauges, flow meters, and water meters scattered across the facility.
ICP DAS’s Automated Water Resource Monitoring: Real-Time Management of Facility Water Usage
In this case, ICP DAS divided the site into three areas and designed the system architecture according to the specific needs of each area.
In Area 1 and Area 3, the water meters record cumulative water consumption. Since they are equipped with Modbus communication capabilities, no additional I/O modules are required. The data is first transmitted wirelessly via ZigBee using the ZT-2550 and ZT-2551 ZigBee RS-485/RS-232 converters, then forwarded to the MDC-711 Modbus Data Concentrators via the Modbus RTU communication protocol.
In Area 2, large-diameter water pipes are equipped with water meters, pressure gauges, and ultrasonic flow meters. The M-7017Z-G Analog Input Module collects water pressure data, while the tM-P8 Digital Input Module, which features a built-in counter function, captures pulse signals from the ultrasonic flow meters. The data is first transmitted wirelessly via ZigBee using the ZT-2550 and ZT-2551 ZigBee RS-485/RS-232 Converters, then forwarded to the MDC-711 Modbus Data Concentrators via the Modbus RTU communication protocol. Finally, all collected data is transmitted to the AVEVA Edge SCADA system in the central control room via the Modbus TCP protocol.
The system architecture diagram is shown below:
Water Pressure Data Collection
In this case, the M-7017Z-G Analog Input Module receives 4-20mA data from the water pressure gauges and transmits it to the ZT-2551 ZigBee RS-485/RS-232 Converter via the Modbus RTU communication protocol.
The M-7017Z-G Analog Input Module provides 10 differential or 20 single-ended analog input channels, allowing users to configure each channel independently. The input range for each analog channel is programmable. Users can select voltage or current input via a jumper setting, and the sampling rate can be adjusted between fast and normal modes. The M-7017Z-G module features overvoltage protection of 240 Vrms and overcurrent protection of 50mA at 110 VDC/VAC. Additionally, it offers 4 kV ESD protection, 3000 VDC intra-module isolation, and supports both Modbus RTU and DCON communication protocols.
Ultrasonic Flow Meter Data Acquisition
In this case, the tM-P8 Digital Input Module operates as a counter, collecting pulse signals from ultrasonic flow meters distributed across the rooftop and basement. The data is then transmitted to the ZT-2551 ZigBee RS-485/RS-232 Converter via the Modbus RTU communication protocol.
The tM-P8 Digital Input Module provides eight digital input channels, each capable of functioning as a counter. It features photocoupler isolation to prevent interference between channels. Additionally, it offers 4 kV ESD protection, 3750 VDC intra-module isolation, and supports DCON, Modbus RTU, and Modbus ASCII communication protocols.
ZigBee Wireless Data Transmission
In this case, the ZT-2551 ZigBee RS-485/RS-232 Converter (Slave) and the ZT-2550 ZigBee RS-485/RS-232 Converter (Master) wirelessly transmit data via ZigBee, reducing wiring costs. The data is then sent to the MDC-711 Modbus Data Concentrator in each area using the Modbus RTU protocol.
The ZT-2551 and ZT-2550 ZigBee Converters are based on the IEEE 802.15.4 standard, enabling the conversion of RS-232 and RS-485 communication interfaces into a ZigBee wireless network. ICP DAS’s ZigBee Series products support a line-of-sight transmission distance of up to 700 meters and operate within a frequency range of 2.405 GHz to 2.48 GHz, offering 16 RF communication channels and 16,384 PAN IDs. The ZT-2000 Series functions not only as a long-range wireless converter but also as a ZigBee coordinator (Master) or router, extending the transmission range and enhancing wireless signal quality. Within a ZigBee network, a single coordinator (Master) can support up to 255 ZigBee routers (Slaves), ensuring a robust and scalable wireless communication infrastructure.
Data Concentrator
The MDC-700 Series Modbus Data Concentrator supports Ethernet, RS-232, and RS-485 communication interfaces, enabling devices that use the Modbus RTU protocol to be upgraded for communication via the Modbus TCP protocol. It consolidates data read from multiple slave devices into a continuous address format, allowing the host system to retrieve data from multiple devices in a single read operation. This approach eliminates the need for traditional polling, significantly reducing data retrieval time. The MDC-700 Series supports up to 8 Modbus TCP masters, allows configuration of up to 250 Modbus RTU commands, and can collect and manage up to 9,600 records for each DI, DO, AI, and AO data type.
Remote Monitoring and Centralized Management
In this case, the AVEVA Edge SCADA system displays and records real-time trend charts of water pressure and flow rate. It also generates reports in CSV, PDF, and Excel formats, enabling more comprehensive water resource management.
AVEVA Edge is a comprehensive, fully integrated SCADA and HMI development platform. It provides essential tools for building powerful applications and supports all Windows runtime platforms, including Windows Embedded Compact, Windows Embedded Standard, Windows 8.1/10/11, and Windows Server Editions (2012/2016/2019). In addition to local operation, AVEVA Edge also supports remote web-based monitoring, offering enhanced convenience and usability.
Benefits:
ICP DAS’s remote I/O modules support various communication protocols and I/O signals, including current, voltage, strain, temperature, and other analog and digital inputs and outputs. To enhance system reliability and stability, they feature a dual watchdog function. The Module Watchdog automatically resets the CPU in case of a module failure and ensures that digital and analog output modules revert to their programmable Power-On Value. Meanwhile, the Host Watchdog monitors communication between the module and the host system, outputting a predefined Safe Value if an anomaly occurs.
The M-7017Z-G Analog Input Module features per-channel open wire detection for 4–20 mA inputs. If the connection between the I/O module and on-site sensors is disrupted, the host system can immediately trigger alarms and activate protective mechanisms.
ZigBee is known for its ease of use, strong anti-interference capability, low cost, and high security. ICP DAS has developed a range of ZigBee products, including signal converters, repeaters, bridges, protocol analyzers, Modbus data concentrators, I/O modules, and sensors, which can be applied in various environments such as industrial control, environmental data acquisition, parking space positioning, building automation, and smart homes.
The MDC-700 Series Data Concentrator features a built-in web server, eliminating the need for additional software installation or programming. Users can conveniently review and configure settings via a web browser, enabling remote monitoring and maintenance to ensure the proper connection of Modbus RTU commands. Furthermore, users can adjust the timeout settings according to the characteristics of connected devices, ensuring enhanced connection reliability.
The data analysis dashboard in AVEVA Edge offers predictive analysis and alerts for water flow and pressure. When values exceed user-defined threshold conditions, the system triggers alarms, notifying maintenance personnel to inspect or replace equipment.
ICP DAS Wastewater Monitoring System: Effective Wastewater Management in Factories Using IoT Technologies
Wastewater monitoring is a crucial aspect of factory water resource management. With an effective wastewater monitoring system, management personnel can track wastewater discharge in real time, ensuring compliance with environmental regulations and preventing potential pollution or leakage that could negatively impact the surrounding environment. Additionally, further implementing a wastewater recycling system can enhance water resource utilization and reduce operational water costs for businesses.
ICP DAS has deployed a wastewater monitoring system in a piston rod manufacturing factory. Multiple WISE Series Intelligent Edge Controllers collect data from sensors across different buildings and floors, including water quality analyzers, differential pressure gauges, and flow meters. The collected data is then transmitted via Ethernet to the AVEVA Edge SCADA system in the control center, where it clearly displays the process water quality, differential pressure, and flow rates on each floor. If an emergency occurs, the on-site WISE Series Intelligent Edge Controllers can instantly trigger alarm notifications via email, Telegram, or WeChat using an IF-THEN-ELSE statement—eliminating the need to wait for commands from the control center.
The WISE Series Intelligent Edge Controller is widely used for edge logic control and monitoring across various industrial settings. Equipped with a built-in IF-THEN-ELSE statement, it efficiently and reliably executes automation logic while supporting functions like mathematical calculations, scheduling, and alarm notifications via email, Telegram, or WeChat. The WISE Series Intelligent Edge Controller offers an easy-to-use web interface that allows users to configure logic rules without needing to write any code. Additionally, the built-in data logger includes a data recovery mechanism: if communication is interrupted, all data is temporarily stored on the module’s SD card. Once the connection is restored, the WISE Series retrieves the data from the SD card and reuploads it to the database, ensuring the integrity of historical data.
Conclusion:
With the global rise of the ESG movement, businesses are not only requiring their partners to provide certification in compliance with the ISO 50001:2018 Energy Management System standard to showcase energy conservation and carbon reduction achievements, but are also increasingly emphasizing the ISO 46001 Water Efficiency Management System standard in response to the rising costs of water consumption.
ICP DAS offers a wide range of solutions for water resource management, covering everything from upstream dams and rivers to midstream and downstream facilities such as water purification plants, cities, factories, and wastewater treatment systems. We provide a comprehensive product line, including sensors, IP cameras, I/O modules, alarm devices, programmable automation controllers (PACs), and edge controllers. Additionally, we offer panel products such as touch HMI devices and LED displays. Committed to solving customer pain points, ICP DAS delivers highly customized and reliable products and solutions, working with you to contribute to ESG and sustainable development.
For more case studies related to water resource management, please refer to the link below:
Strengthening Climate Resilience: ICP DAS Water Resource Management Solutions
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ICP DAS was established in 1993 and strongly focuses on innovation and the enhancement of industrial automation technology. ICP DAS continuously endeavors to develop a comprehensive selection of products ranging from remote I/O controllers, distributed I/O modules, I/O data acquisition boards, programmable automation controllers, industrial communication modules, web-related products, motion control systems, SCADA/HMI software to automation solutions for applications critical to energy management, motion automation, smart factories, intelligent buildings, and smart cities. Our ambition is to provide a wide range of high-quality products and versatile applications, together with prompt and efficient services, that can be implemented to assist in the continued success of our clients worldwide.