Development of Wireless Serial Server Module for the Remote operation of various Serial Field Device in ITER-India

Serial communication finds widespread usage in industrial control systems due to its immense benefits including simplicity, reliability, and interoperability. Traditionally, the RS232 and RS485 networks have become the standard for connecting various devices and equipment for serial communication. On the otherside, wireless networks are making its way for use in industrial control system applications. The installation of wireless networks naturally provides a reduction in cable and its maintenance related costs, provides increased flexibility and mobility to enhance the performance of industrial control system. In this context, the prototype of serial wireless server module has been designed and developed successfully to operate industrial field devices with inbuilt RS232 port over Wi-Fi network. Primarily, this module converts serial data in RS232 network in Wi-Fi IEEE 802.11n format and vice versa using TCP communication. The serial wireless module is configured as a TCP server. The remote computer(PC), configured as TCP client, connects to this Wi-Fi network and remote serial device can be accessed using software application in PC. This module has multiple advantages such as completely wireless, portable, independent of auxiliary device, USB operated, plug-n-play and of easy to deploy type. The multiple modules, connected to different field devices, can be connected in one Wi-Fi subnet and accessed from single PC for control & data acquisition purpose.This paper presents the design, development and deployment of this module in detail. This module is currently installed in Pfeiffer Vacuum Gauge Controller (TPG 256A) along with custom developed windows application in PC. This application displays current pressure gauge values, saves pressure values in SQL database, can export data to Excel sheet, can configure threshold set points for digital alarm generation and act on the devices such as gate valve etc.