Tier 1 Single Pump Station Kit
$2,034
Monitors 3-5 pumps. Start/stop control. VFD speed control. ML inference at the edge. Cloud sync. Everything to read sensors (pressure, temperature, flow, vibration, current, speed, status), control pump contactors, drive VFD speed, and run anomaly detection.
| # | Component | Purpose | Qty | Price | Buy |
|---|---|---|---|---|---|
| 1 | RevPi Connect 58GB RAM, RS-485, CAN FD. Model 100417 or 100419 | Main compute unit. ARM64 quad-core 2.4GHz, 2x GbE, DIN-rail, CE/UL certified. Runs TwinEdge OS + OpenPLC side by side. | 1 | $700 | revolutionpi.com |
| 2 | RevPi AIOAnalog I/O module (PiBridge) | 4x 4-20mA inputs (16-bit) for pressure, flow, vibration, current. 2x 0-10V/4-20mA outputs for VFD speed. 2x PT100 RTD for temperature. | 1 | $370 | revolutionpi.com |
| 3 | RevPi DIODigital I/O module (PiBridge) | 14x 24VDC inputs for run/stop status, proximity speed sensors, limit switches, seal leak. 14x 24VDC outputs (500mA) for VFD run/fwd commands. | 1 | $230 | revolutionpi.com |
| 4 | Sequent Microsystems 4-Relay HATStackable, I2C, 8A/240VAC per relay | 4x relay outputs per HAT. Switches contactor coils to start/stop pumps. Works with 24VDC and 240VAC coils. Hardware watchdog de-energizes on Pi crash. | 2 | $200 | sequentmicrosystems.com |
| 5 | Sequent Microsystems RTD HAT8x PT100/PT1000, 24-bit, 0.1% accuracy | Reads bearing temperatures (drive end + non-drive end) on each pump. 3-wire connection with automatic lead resistance compensation. | 1 | $95 | sequentmicrosystems.com |
| 6 | Sequent I/O Back Panel (4-slot)DIN-rail mounting frame | Mounts up to 4 stacked Sequent HATs on standard 35mm DIN rail inside an industrial panel. | 1 | $120 | sequentmicrosystems.com |
| 7 | Mean Well HDR-60-24DIN-rail 24VDC / 60W power supply | Powers all 4-20mA sensor current loops, I/O modules, and contactor coils. 24VDC / 2.5A. DIN-rail mount. | 1 | $30 | mouser.com |
| 8 | Pilz PNOZ s4Safety relay, dual-channel, Cat 4 / SIL 3 | Hardwired E-stop circuit. Interrupts contactor power independent of PLC. Required for any pump control. Works even if Pi is dead. | 1 | $160 | pilz.com |
| 9 | SanDisk MAX Endurance 32GBIndustrial microSD card | High-endurance storage for TwinEdge OS. Rated 15,000 hours continuous write. Industrial temperature range. | 1 | $15 | amazon.com |
| 10 | Phoenix Contact UTKN 2.5DIN-rail screw terminal blocks (10-pack) | Field wiring termination. Connect sensor and actuator wires to I/O modules. 2.5mm2 rated. | 2 packs | $50 | phoenixcontact.com |
| 11 | DIN Rail, 35mm TS35, 500mmAluminum, standard profile | Mounts all components: RevPi, I/O modules, PSU, safety relay, terminal blocks. | 1 | $8 | automationdirect.com |
| 12 | DIN-rail end stopsSnap-on, metal clip | Prevents components from sliding on the rail. | 2 | $6 | automationdirect.com |
| 13 | Wire ferrules kitAssorted 0.5-2.5mm2 bootlace with crimper | Crimp ferrules on stranded wire ends before inserting into screw terminals. Prevents fraying. Required for reliable connections. | 1 kit | $40 | amazon.com |
| 14 | Ethernet cable, Cat6, 1mIndustrial rated, shielded | Connects RevPi ETH0 to field network switch for Modbus TCP to other devices. | 2 | $10 | Any industrial supplier |
Tier 1 Total
$2,034
I/O Capacity
| I/O Type | Channels | Connects To |
|---|---|---|
| 4-20mA analog inputs | 4 (16-bit) | Pressure transmitters, flow meters, vibration transmitters, motor CTs |
| Analog outputs (0-10V / 4-20mA) | 2 (16-bit) | VFD speed reference |
| PT100 RTD temperature inputs | 10 | Bearing temps, motor winding temps |
| 24VDC digital inputs | 14 | Run/stop status, proximity speed sensors, limit switches, seal leak |
| 24VDC digital outputs | 14 (500mA) | VFD run/fwd/rev commands, indicator lights |
| Relay outputs (8A / 240VAC) | 8 | Pump start/stop contactors (up to 8 pumps) |
| RS-485 serial | 1 | Modbus RTU to legacy devices |
| CAN FD | 1 | CANopen devices |
Enough for 5 pumps with full sensor suite + start/stop + VFD speed control on 2 pumps.
Safety note: The Pilz PNOZ s4 safety relay provides a hardwired E-stop circuit that operates
independently of the PLC. The PLC relay output is wired in series with the safety relay. Both must be closed
for the contactor to energize. If the Pi crashes, the safety relay still works. Motor overload protection
is also separate, already in the motor control center.
Tier 2 Full Treatment Plant Kit
$3,293
Everything in Tier 1 plus additional I/O for 12+ process stages, 50+ sensors, and 8 serial buses to connect to existing PLCs via Modbus RTU. The additional Sequent HATs stack on top of the Tier 1 HATs using the I2C bus (each set to a different address via onboard DIP switch).
Includes all 14 items from Tier 1 ($2,034)
| # | Component | Purpose | Qty | Price | Buy |
|---|---|---|---|---|---|
| 15 | Sequent Industrial Automation HAT4x 4-20mA + 4x 0-10V + 4 DI + 4 DO + RS-485 | All-in-one I/O for additional process stages. 4x 4-20mA inputs (12-bit), 4x 0-10V inputs (16-bit), 4x isolated DI, 4x MOSFET DO (4A/24VDC), RS-485 port. | 2 | $240 | sequentmicrosystems.com |
| 16 | Sequent 8-ch 4-20mA Input HAT8 channels, optically isolated, 12-bit | 8 additional 4-20mA inputs per HAT for chemical feed systems, clarifier levels, filter head loss, effluent quality sensors. | 2 | $190 | sequentmicrosystems.com |
| 17 | Sequent RTD HAT (additional)8x PT100/PT1000, 24-bit | 8 more PT100 channels for process temps, chemical tank temps, effluent temps. | 1 | $95 | sequentmicrosystems.com |
| 18 | Sequent 4-Relay HAT (additional)4x relay, 8A/240VAC | 4 more relay outputs for chemical feed pumps, valve actuators, blower contactors. | 1 | $100 | sequentmicrosystems.com |
| 19 | Sequent Eight Serial Ports HAT8x RS-485/RS-232 ports | Connects to up to 8 existing PLCs, VFDs, or analyzers via Modbus RTU. Critical for brownfield plants with existing equipment. | 1 | $95 | sequentmicrosystems.com |
| 20 | Sequent I/O Back Panel (8-slot)DIN-rail mounting frame, large | Larger DIN-rail frame to hold all additional Sequent HATs. Use alongside the 4-slot from Tier 1. | 1 | $150 | sequentmicrosystems.com |
| 21 | RevPi AIO (second unit)Analog I/O module (PiBridge) | 4 more 16-bit 4-20mA inputs + 2 more analog outputs for additional VFD speed control or chemical dosing pump speed. | 1 | $370 | revolutionpi.com |
| 22 | Mean Well HDR-100-24Upgrade: DIN-rail 24VDC / 100W | Replaces the 60W PSU from Tier 1 to power additional sensor loops. 24VDC / 4.2A. | 1 (replaces #7) | +$15 | mouser.com |
Tier 2 Total (includes Tier 1)
$3,293
Cumulative I/O Capacity
| I/O Type | Channels | Connects To |
|---|---|---|
| 4-20mA analog inputs (16-bit) | 8 | High-precision: pressure, flow, critical process sensors |
| 4-20mA analog inputs (12-bit) | 24 | Chemical feed, levels, turbidity, pH, ORP, dissolved oxygen |
| 0-10V analog inputs | 8 | Valve position feedback, level sensors |
| Analog outputs (0-10V / 4-20mA) | 12 | VFD speed, chemical dosing pump speed, valve positioners |
| PT100 RTD temperature inputs (24-bit) | 26 | All bearing temps, motor temps, process fluid temps |
| 24VDC digital inputs | 22 | Status, alarms, limits, proximity sensors |
| 24VDC digital outputs | 22 | VFD commands, solenoid valves, indicator lights |
| Relay outputs (8A / 240VAC) | 12 | Pump, blower, chemical feed pump contactors |
| RS-485 serial ports | 11 | Modbus RTU to existing PLCs, VFDs, analyzers |
Enough for a 12-stage treatment plant with 50+ sensors, 12 motor contactors, 8 Modbus RTU buses to legacy equipment.
Tier 3 Production Deployment Kit
$4,403
Everything in Tier 2 plus remote connectivity (4G LTE), battery UPS backup, weatherproof enclosure, ambient monitoring, a hot spare unit, and industrial network switching for unattended remote sites.
Includes all 22 items from Tier 2 ($3,293)
| # | Component | Purpose | Qty | Price | Buy |
|---|---|---|---|---|---|
| 23 | Quectel EC25-AF Mini PCIe4G LTE Cat 4 modem (150 Mbps) | Cellular connectivity for remote/unmanned sites with no Ethernet. Enables cloud sync, OTA updates, and remote access over LTE. | 1 | $45 | digikey.com |
| 24 | 4G LTE antenna, SMA maleAdhesive mount, MIMO pair | External antennas for the LTE modem. Adhesive or magnetic mount for panel enclosure. | 2 | $16 | amazon.com |
| 25 | Industrial IoT SIM cardMulti-carrier global, data-only | Monthly cellular data. Telemetry uses 500MB-2GB/month depending on reporting interval. | 1 | $10/mo | hologram.io |
| 26 | Mini PCIe to USB 3.0 adapterFor LTE modem connection | Connects the EC25 LTE modem to RevPi's USB 3.0 port. | 1 | $15 | amazon.com |
| 27 | Mean Well DR-UPS40DIN-rail UPS module, 24VDC | Battery-backed power for clean shutdown on power loss. Seamless switchover. Gives 10-30 minutes to save state and alert cloud. | 1 | $85 | mouser.com |
| 28 | 12V 7Ah SLA batterySealed lead-acid, maintenance-free | Battery for UPS module. Two in series for 24V. Provides 15-20 minutes runtime during power outage. | 2 | $40 | amazon.com |
| 29 | Sequent Building Automation HATAmbient temp/humidity + mixed I/O | Onboard DHT22 sensor monitors panel enclosure temperature and humidity. 4x 0-10V inputs, 4x relay, 4x DI for additional I/O. | 1 | $100 | sequentmicrosystems.com |
| 30 | Fibox ARCA 400x300x210mmIP65 NEMA 4X polycarbonate enclosure | Weatherproof enclosure for outdoor or harsh environments. UV resistant. Mounts all DIN-rail components inside. | 1 | $180 | automationdirect.com |
| 31 | Cable glands PG13.5/PG16 IP68Assorted sizes, weatherproof | Weatherproof cable entry points for NEMA enclosure. For sensor cables, Ethernet, and power. | 10 | $20 | automationdirect.com |
| 32 | RJ45 Cat6 IP67 bulkheadPanel-mount, weatherproof Ethernet pass-through | Weatherproof Ethernet connection through the enclosure wall. | 2 | $24 | amazon.com |
| 33 | RevPi Connect 5 (spare unit)8GB RAM, same model as #1 | Identical hot spare. Pre-flash with TwinEdge OS. If primary fails, swap and restore from cloud config sync in under 15 minutes. | 1 | $700 | revolutionpi.com |
| 34 | Moxa EDS-205A5-port unmanaged industrial Ethernet switch, DIN-rail | Connects RevPi to field network devices (PLCs, VFDs with Modbus TCP, IP cameras). Metal housing, -10 to 60C. | 1 | $75 | moxa.com |
Tier 3 Total (includes Tier 1 + 2)
$4,403 + $10/mo cellular
What Tier 3 Adds
| Capability | Spec | Why It Matters |
|---|---|---|
| 4G LTE cellular | 150 Mbps | Cloud sync from sites with no Ethernet or WiFi |
| Battery UPS | 15-20 min | Clean shutdown, alert cloud, save PLC state on power loss |
| Outdoor enclosure | IP65 / NEMA 4X | Weatherproof for outdoor or wet environments |
| Ambient monitoring | Temp + humidity | Alerts if enclosure overheats or condensation risk |
| Hot spare | Pre-configured | Swap in under 15 minutes. Cloud restores all settings. |
| Industrial switch | 5-port GbE | Connect multiple field devices on local Ethernet segment |
Side-by-Side Comparison
| Tier 1 ($2,034) | Tier 2 ($3,293) | Tier 3 ($4,403) | |
|---|---|---|---|
| Use case | Pump station (3-5 pumps) | Treatment plant (12+ stages) | Remote production site |
| 4-20mA inputs | 4 (16-bit) | 32 (mixed) | 32 |
| 0-10V inputs | 0 | 8 | 12 |
| Analog outputs | 2 | 12 | 12 |
| RTD inputs | 10 | 26 | 26 |
| Digital inputs | 14 | 22 | 26 |
| Digital outputs | 14 | 22 | 22 |
| Relay outputs (240VAC) | 8 | 12 | 16 |
| RS-485 serial ports | 1 | 11 | 11 |
| 4G LTE cellular | No | No | Yes |
| Battery UPS | No | No | Yes (15-20 min) |
| Outdoor enclosure | Panel mount | Panel mount | IP65 NEMA 4X |
| Hot spare | No | No | Yes |
| ML inference | Yes (<50ms) | Yes (<50ms) | Yes (<50ms) |
| Cloud sync | Ethernet | Ethernet | Ethernet + 4G |
| PLC control (OpenPLC) | Yes | Yes | Yes |
| Safety relay (E-stop) | Yes (Pilz) | Yes (Pilz) | Yes (Pilz) |
Note Field-Supplied Equipment (Not Included)
Sensors and actuators typically already installed on the pump or purchased from the sensor vendor specific to the application. These are NOT part of the TwinEdge PLC kit.
| # | Component | Purpose | Typical Cost | Notes | |
|---|---|---|---|---|---|
| a | 4-20mA pressure transmittere.g., Rosemount 2088 | Measures suction and discharge pressure on each pump. | per pump | $300-800 | Usually already installed |
| b | 4-20mA vibration transmittere.g., Wilcoxon iT300 | Converts raw accelerometer signal to 4-20mA for PLC input. Raw IEPE sensors do not connect directly. | per pump | $200-400 | Required adapter |
| c | PT100 RTD sensors (3-wire)Bearing housing insert | Measures bearing and motor winding temperatures. | per pump | $20-80 | Usually pre-installed |
| d | Electromagnetic flow metere.g., Endress+Hauser Promag | Measures flow rate. Outputs 4-20mA proportional to flow. | per pipe | $1,500-5,000 | Already in piping |
| e | Split-core current transformere.g., CR Magnetics CR5210, 4-20mA output | Clamps around motor phase conductor to measure current. No wiring changes needed. | per motor | $80-150 | Non-invasive install |
| f | Inductive proximity sensor (24VDC PNP)For shaft speed measurement | Aimed at shaft keyway or reflector. Outputs 24VDC pulse per revolution. | per pump | $30-60 | Mount near coupling |
| g | Motor contactore.g., ABB AF09-30, Schneider LC1D | Switches motor power (3-phase). Controlled by PLC relay via coil. | per motor | $50-200 | Already in MCC |
| h | VFD (variable frequency drive)e.g., ABB ACS580, Schneider ATV320 | Controls pump motor speed. Accepts 0-10V or 4-20mA from PLC for speed setpoint. | per pump | $500-3,000 | Already installed if variable speed |
| i | Panel wiring18-16 AWG stranded, various colors | Standard panel wire for connecting I/O terminal blocks to sensors and actuators. | 1 lot | $50-100 | Standard supply |