EM100 ESP32-S3 Edge PLC Controller with Modular I/O

Edge PLC Controller Applications

1. Expanding Monitoring in Existing Plant Systems

When a plant adds new measurement points, it often needs to connect RS485 instruments and individual sensor signals to an existing Ethernet-based monitoring system. The EM100 edge PLC controller collects data from Modbus instruments and expansion I/O, converts readings into engineering values, and makes them available to the SCADA system over Modbus TCP.

With Modbus RTU-to-TCP conversion, plants can expand temperature, pressure, and flow monitoring while keeping their existing SCADA system. Operators can still view the new field data through the same interface they already use, without having to adapt to a separate monitoring interface.

2. Automatic Cooling for Control Cabinets

Control cabinets need ventilation based on changes in internal temperature. Switching fans manually takes time. If the same temperature value is used to start and stop a fan, the fan may cycle frequently when the temperature fluctuates around that value.

The EM100 edge PLC controller combines temperature acquisition with local rule-based automation. It uses separate start and stop thresholds and controls the fan through a suitable output driver. Its modular I/O connects temperature inputs and fan control outputs, so temperature evaluation and control execution take place at the cabinet. This reduces manual intervention and helps limit frequent fan cycling.

3. Remote Monitoring and Control of Pumps and Valves

At distributed pump stations and water management facilities, checking operating conditions and adjusting equipment settings often require multiple site visits. The EM100 edge PLC controller supports industrial IoT monitoring by reporting pressure, flow, and equipment status to an MQTT platform and mapping commands from the platform to pump start/stop controls or valve setpoints.

Through MQTT communication, the EM100 also reports the actual measured status back to the platform, so operators can verify the equipment response after issuing a command. This gives operations teams a central view of field conditions and supports remote monitoring and control, reducing site visits made only to read data or change settings.

FAQ

1. Can I use EM100 with my existing PLCs and instruments?

EM100 works with devices that support Modbus RTU or Modbus TCP. Sensors with digital or analog signals can connect through compatible I/O expansion modules. Before selecting a configuration, check your equipment’s protocol, register map, and signal type—an RS485 or Ethernet port alone does not confirm compatibility.

2. Can EM100 directly control pumps, fans, or valves?

EM100 can provide switching signals or analog setpoints through the appropriate output modules. Whether an output can connect directly to a load depends on the module’s electrical rating and the equipment’s requirements. Use a suitable relay, contactor, or driver where needed; motor power should not be connected directly to an I/O output.

3. Can I connect EM100 to our own platform?

Yes. EM100 supports MQTT and TCP communication, with configurable JSON templates and fields for exchanging data with compatible platforms. You can use your existing system, provided its connection settings, authentication requirements, and message format are supported by EM100.

4. Will EM100’s 4G connection work in my country?

Compatibility depends on the cellular bands used by your local carrier. The supplied specification lists LTE-FDD bands B1/B3/B5/B8 and LTE-TDD bands B34/B38/B39/B40/B41. Confirm the supplied model’s band support and SIM compatibility with your carrier before ordering.

5. Do I need to visit the site for every device update?

EM100 supports remote maintenance, device management, and upgrades, so supported service tasks can be handled remotely once network access is established. Physical work, such as changing wiring, replacing modules, or servicing connected equipment, still requires an on-site visit.

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