FlowChief Connect (FC_Connect)

FlowChief Connect transforms standard PLC assemblies into intelligent remote control stations using specialised libraries. The solution enables secure, event-driven capturing, buffering and transmission of data from distributed systems.

As a manufacturer-independent gateway (OPC Classic oder OPC UA1) , FlowChief Connect ensures bidirectional data flow between the field level and the FlowChief platform as well as external IoT portals or databases.

Your retrofit opportunity: Use FlowChief Connect to make existing systems (e.g. Siemens S7-300) IoT-compatible without replacing hardware and connect them seamlessly to the FlowChief platform or third-party systems.

Highlights & Benefits

  • Firewall-friendly (push principle): The station actively establishes the connection. No open ports on the system, no static IPs required – a decisive advantage for your IT security.

  • Conversion of standard PLCs into remote control stations: Utilise existing or commercially available hardware (Siemens, Phoenix Contact, Wago, Beckhoff, etc.) without expensive special hardware.

  • Gapless data history: Integrated buffering of data on the control system in the event of connection interruptions (up to 20 days). As soon as the connection is re-established, data is delivered with the correct time stamp.

  • Maximum security: End-to-end encrypted transmission (TLS) and VPN compatibility protect your critical infrastructure data.

  • Cost-optimised transmission: Event-driven transmission (push) instead of polling minimises the data volume.

  • Flexibility in transmission: Whether 4G/5G, LTE-M, 450MHz, SHDSL or classic network/intranet – FlowChief Connect adapts to the infrastructure.

  • Simple engineering: Pre-built libraries drastically reduce the amount of programming required on the controller.

FlowChief Edge Controller

  • For users who prefer an out-of-the-box solution, the FlowChief Edge Controller is available.

  • All-in-one solution: Industrial controller with pre-installed Connect runtime environment.

  • Zero-touch deployment (ZTD): No local PLC programming or engineering software required.

  • Flexible field connection: Direct acquisition via onboard I/Os (digital, analogue, counters) and via Modbus TCP, including intelligent pre-processing and buffering of data.

  • Over-the-air configuration: Complete parameterisation is conveniently carried out directly from the control system – configuration changes are transferred to the device at runtime.

  • Ideal for: Efficient retrofit measures, self-sufficient data collectors or systems without existing PLC infrastructure.

Typical areas of application for FlowChief Connect

  • Water/wastewater: Seamless monitoring of elevated tanks, pumping stations and storm water overflow basins (RSB) – even with unstable mobile phone coverage.

  • Energy: Networking of decentralised generators (PV parks, wind), local network stations and smart metering for critical infrastructures.

  • Infrastructure: Reliable data acquisition for traffic engineering (tunnels), environmental levels and digital neighbourhood management.

  • Industry: Energy management and process data acquisition. Integrated buffering and time stamping guarantee correct balances (e.g. for ISO 50001).

  • Plant and mechanical engineering (OEM): Global remote service, condition monitoring and standardised connection of series machines to IoT clouds.

 

FlowChief Connect
Details
Central interface OPC Classic DA; OPC UA incl. HA (FlowChief Security Gateway)2
Communication principles

Active transmission from station (push), event triggered & cyclic

Data security Integrated TLS encryption (system dependent), VPN compatible
Data buffer

Yes, ring buffer on PLC (local timestamp). Capacity depending on storage depth / interval (up to 20 days).

Connection management

Integrated connect intelligence, watch dog monitoring

Alerting SMS dispatch via FlowChief router (system dependent) via central
Redundancy Support of redundant centrals and streams
Multi-Connectivity

Simultaneous connection to multiple targets possible (system dependent)

Licensing
Optionales Add-on
  • Packages can be accumulated randomly (e.g. FCConnect_10+ FCConnect_1 = 11 stations)

    • Available sizes: 1, 3, 5, 10, 25, 50 stations

  • Packages for standard license type only (web.HMI includes one FlowChief Connect station at delivery– an extension is not possible)

Functionality

The substation: The FlowChief Connect library is installed on the standard PLC. This takes care of connection management, buffering values and compiling data packets in the event of connection loss. Data is actively sent from the station to the control centre (no polling), which minimises the data volume.

Transmission: Communication takes place via TCP/IP. The connection can be secured via public networks (mobile communications, Internet) using TLS. The control system actively establishes the connection, which facilitates use in protected mobile communications networks without a fixed IP address.

The control center: The FlowChief Connect Server receives the data, unpacks the timestamp history, and makes the current values and alarms available to the control system via a standardized OPC interface.

Supported Controllers (compatibility matrix)

FlowChief Connect is manufacturer independent. The following manufacturers and their systems are supported:

Manufacturer System family Development Environment Notes Hostname-Resolution TLS-Encryption SMS Dispatch3 Multi-Connectivity4

Siemens

S7-300 TIA16 - TIA21 From Firmware 2.6     X X
S7-1200 TIA16 - TIA21
TIA21 Firmware 4.7
TIA20 Firmware 4.7
TIA19 Firmware 4.6
TIA18 Firmware 4.6
TIA17 Firmware 4.5
TIA16 Firmware 4.4
X X X X
S7-1500, ET2000SP TIA16 - TIA21
TIA21 Firmware 4.1
TIA20 Firmware 4.0
TIA19 Firmware 3.1
TIA18 Firmware 3.0
TIA17 Firmware 2.9
TIA16 Firmware 2.8
X X X X
S7-1200G2 TIA16 - TIA21
TIA21 Firmware 4.1
TIA20 Firmware 1.0
X X X X

PLCNext PLCNext Engineer   X5 X X X

Beckhoff

Embedded-PCs (Arm® Cortex®, Intel Atom®, AMD Ryzen™, Intel® Xeon®) TwinCat 3       X X
Embedded-PCs (Arm9™) TwinCat 2          

Controller 750-88x, 750-84x Wago-I/O-Pro (CoDeSys 2.3)   X X X X
PFC100 Codesys 3.5,
e!COCKPIT
  X   X X
PFC200 Gen1 e!COCKPIT,
WAGO-i/O-Pro (CoDeSys 2.3)
  X   X X
PFC200 Gen2 CoDeSys 3.5   X   X X
PFC300, Compact Controller CoDeSys 3.5   X   X X

Panasonic

FP7, FP0H FPWinPro          

ABB

AC500V2 Automation Builder (CoDeSys 2.3)          

B&R

X20 System Automation Studio   X      

Eaton

XC100 (CPU101), XC (CPU 201/202), CX152 Xsoft-CoDeSys-2         X
XC100 (XC-104-…), XC200 (XC-204..), XC300 (XC303-…) Xsoft-CoDeSys-3   X   X X
Yaskawa SLIO/300S+ Simatic Manager       X X
FlowChief EdgeCo (PLCNext)   Plug & Play X X X  

This overview is not exhaustive. If you require support for a manufacturer not listed here, a specific control series or a special function, we will be happy to implement your project. Contact us directly – we will find the right solution for you.

Is your CODESYS 3.5-based hardware manufacturer not listed? Since CODESYS works independently of manufacturers, we support almost every device ecosystem. Please contact us to discuss your specific hardware.