© 2005 Fairmount Automation, Inc. All Rights Reserved. Reduce Cost, Size, and Weight Programmable Automation Controllers (PAC) July 21, 2005

© 2005 Fairmount Automation, Inc. All Rights Reserved.

Reduce Cost, Size, and Weight

Programmable Automation Controllers (PAC)

July 21, 2005

2© 2005 Fairmount Automation, Inc. All Rights Reserved.

Founded in 1996 Located in Suburban Philadelphia, PA OEM of Programmable Automation Controllers Products Installed on Over 30% of U.S. Navy Fleet Leadership Role in Design and Development of

Automated Damage Control Systems for DD(X)

About Fairmount Automation

Engineering

Services

Product

Development


Designed and implemented leading-edge Autonomic Fire Suppression System (AFSS)

Based on embedded smart-valve technology Distributed device-level control (LonTalk protocol) Successful Weapon Effect Test (WET) on

ex-USS Peterson (first ever) Successful live-fire tests on ex-USS Shadwell Anticipate central role in DD(x) Flight I ADCS design Process improvement initiative underway to achieve

CMMi Level 3 assessment (sponsored by Raytheon)

DD(X) AFSS


First Generation FAC-2000

MIL-SPEC Grade A Shock, MIL-SPEC Vibration Programmable Digital Multi-Loop Controller User-Friendly, Hardened Integral Operator Interface Initially Installed in 1997 to Overhaul Legacy Controls

Reactor Secondary Steam Plant Controls Catapult Accumulators Primary Boiler Controls Main Feed Pumps Distilling Plants Evaporators

USS John F Kennedy


Over 1500 Loops of Control Aircraft Carriers Amphibious Assault Amphibious Transport Destroyers Cruisers Frigates Combat Support Ships Submarine Supply Ships

Current Installed Base

USS Boone


Installed Applications

Propulsion Boilers Feed Pumps Distilling Plants Waste Heat Boilers Condensers Evaporators Oil and Fuel Heaters Steam Turbine Aux. Diesel Generator Aux.

Force Draft Blowers Deaereating Feed Tanks Chilled Water Plants Catapult Accumulators Compressors Purifiers Compressors Shaft Speed Indication

USS Ticonderoga


Chameleon: New Controller Platform


Key Characteristics

MIL-SPEC qualified “out-of-the-box”

Eliminates need for costly, bulky, and heavy enclosures

Distributed processor architecture enhances survivability

Open connectivity to industry standard protocols and networks

Flexible and modular architecture with versatile I/O suite

Easy to assemble, install, and maintain

Integrated user-interface with prominent displays and buttons

Wireless device configuration and data retrieval


In ter-M oduleO -R ing

E nd C ap

E nd C apO -R ing

S hock M ountingFoot

Fu ll-S ize M odu leE nclosure

E nd C ap

E nd C apO -R ing

H alf-S ize M odu leE nclosure

H alf-S ize C overand A ctive B oard

W ater-T igh tC able G lands

Full-S ize C overand A ctive B oard

C over M ountingS crews

H alf-S izeC onnection B oard

Full-S izeC onnection B oard


Chameleon PAC Installations

350+ Chameleon Modules In Service (U.S. Navy)

Currently Installed on 20 U.S. Navy Ships:

USS IWO JIMA USS VANDERGRIFT USS DUBUQUE

USS BOONE USS JOHN HALL USS WASP

USS DOYLE USS UNDERWOOD USS PONCE

USS DEWERT USS KAUFFMAN USS FORD

USS GARY USS ESSEX USS SIMPSON

USS BRADLEY USS CLEVELAND USS PELELIU

USS NASHVILLE USS MCINERNY


FFG-7 Class SSDG Aux. Control

Decentralized Control Architecture 5 Networked Chameleon Nodes 9 PCM-1, 6 NIM-1, 5 ACP-1

Installed on 10 Ships; Approved for Entire Class Control Loops Include

Fuel Oil Transfer and Service Heaters Main Engine Lube Oil Purifier Heater, Start Air Cooler Main Engine Lube Oil Cooler, Lube Oil Pressure Hot Water Tank SSDG Waste Heat Temperature SSDG Jacket Water Temperature

Networked to flat screen to provide plant-wide information and remote control

USS Doyle


FFG-28 Installation Pictures


LHA-1 / LHD-1 Class SSTG Aux. Control

Decentralized Control Architecture 3 Networked Chameleon Nodes 5 PCM-1, 3 NIM-1, 3 ACP-1

Installed on 4 Ships; 2 more to begin in October Control Loops Include

SSTG Hotwell Level SSTG Recirc Temperature SSTG Gland Seal Pressure Control

Fully networked Plant-wide information accessible at any node via

wireless infrared interface

USS Peleliu


LHD-1 Installation Pictures


LPD-4 Class Chilled Water Control

Decentralized Control Architecture 5 Networked Chameleon Nodes 9 PCM-1, 5 NIM-1, 5 ACP-1, 2 UCM-2AMI

Installed on 3 Ships Expanded system to be installed on LPD-9 in Q4 Control Loops Include

Flow rate thru chiller pump with local A/M control Cooling water for condenser

Monitor expansion tank level and pressure Monitor condenser outlet pressures Networked to flat screen to provide plant-wide

information and remote control USS Cleveland


Automatic Burner Ignition System

Two Nodes (4 DAM-2, 2 PCM-1, 2 NIM-1, 2 ACP-1) Installed on USS IWO JIMA (LHD-7); LHD-2 next Burner light-off system for main propulsion boiler Monitors atomization pressure, windbox pressure,

fuel-oil pressure, and port-use fan speed Controls burner fuel flow, ignition arm position, and

ignition spark Coordinated control from burner front, EOS, or both Future expansion to include

Full burner management system Integration with FAC2000-based Automatic Boiler Controls Fully automated throttle control from the bridge

USS Iwo Jima


Manual Boiler Light-Off


Shaft-Speed Indication System

Two Nodes 2 PCM-1, 2 NIM-1, 6 ACP-1, 4 UCM-1, 2 NBM-1

Installed on USS PONCE (LPD-15); LCC-19 next Port and starboard shaft quadrature encoders inputs Calculates RPM and maintains shaft revolution count Provides redundant power supplies for remote RPM

displays Interfaces with external display using NMEA protocol

Implemented with our user-defined ASCII messaging Applicable to every ship in the Fleet

USS Ponce


LPD-15 Installation Picture


Key Characteristics: Packaging

MIL-SPEC qualified “out-of-the-box” High Impact Shock: MIL-STD-901D (Grade A, Class I) Mechanical Vibration: MIL-STD-167B Electro-Magnetic Interference: MIL-STD-461E (Pending) Power Spikes: MIL-STD-1399

Designed for shipboard environments Operating Ambient Temperature Range: -40°C to 65°C Keypad & Housing: NEMA 4X, 6, and 13

Eliminates need for costly, bulky, and heavy enclosures Easy to assemble, install, and maintain Integrated user-interface with prominent displays and

buttons


Key Characteristics: Packaging


Key Characteristics: Modular Design

Multi-Processor architecture enhances survivability Each module is self-contained controller Deterministic performance (sub 10ms)

Facilitates future technology insertion Open connectivity to standard protocols and networks Versatile I/O suite All modules are hot-swappable Highly granular redundancy

I/O connections Control execution Power sources Network connections


Key Characteristics: Modular Design

In ter-M oduleO -R ing

End C ap

End C apO -R ing

Shock M ountingFoot

Fu ll-S ize M odu leEnclosure

End C ap

End C apO -R ing

H alf-S ize M odu leEnclosure

H alf-S ize C overand Active Board

W ater-T igh tC able G lands

Full-S ize C overand Active Board

C over M ountingScrews

H alf-S izeC onnection Board

Full-S izeC onnection Board


Key Characteristics: Design Flexibility

Local controller for OEM equipment Strainers Chillers Pumps Generators Valves

Remote I/O drop Connectivity to central PLC Potential integration with Smart Carrier program

Decentralized and highly-survivable ship-wide machinery control and monitoring system


MCMS Conventional I/O Drop

Enclosure to House PLC or VME-based control hardware Din-rail mounted terminal points Power supplies / conditioners Network media converters Assume 24” x 24” x 8.5”

Require shock mounts Coily mounts C-Worthy mounts (adds 5.5” to depth) Angle spot weld studs mount to ship (adds 2” to depth)

Signal densities 50-100 I/O points typical, approximately 160 maximum Assume 100 points per enclosure for this example

Total weight 140 lbs typical (including mounts) Assume 90 lbs per enclosure is achieved for this example


MCMS Chameleon I/O Drop

Integrated Package All power supply, media converters,

terminal points, etc. Sample I/O drop configuration

2 power modules, 2 network modules, 8 I/O modules

Dimensions: 24” x 24” x 6.5” Chameleon node 3-row mounting bars Angle or studs connect bars to ship

Signal density 96 to 144 I/O points with currently available modules Assume 100 points on average for this example

Total weight: 40.5 lbs Chameleon nodes 20 lbs, Mounting bars 10.5 lbs, Other 10 lbs

24.0

24.0


MCMS Chameleon Mini-I/O Drop

Integrated Package All power supply, media converters,

terminal points, etc. Sample mini-I/O drop configuration

1 power module, 1 network module, 2 I/O modules

Dimensions: 16.5” x 11.5” x 6.5” Chameleon node 2-row mounting bars Angle or studs connect bars to ship

Signal density 24, 30, or 36 I/O points with currently available modules Assume 25 points on average for this example

Total weight: 16 lbs Chameleon node 7.5 lbs, Mounting bars 3.5 lbs, Other 5 lbs

11.5

16.5


CVN-21 MCMS I/O Drop Comparison Assume example platform has 20,000 I/O points Conventional I/O Drop

200 drops required Volume: 5.33 ft3 per drop, 1,067 ft3 total Weight: 90 lbs per drop, 18,000 lbs total Cost Estimate (Avg.): $25,000 per drop, $5.0MM total

Chameleon I/O Drop 200 drops required Volume: 2.17 ft3 per drop, 433 ft3 total Weight: 40 lbs per drop, 8,100 lbs total Cost Estimate (Avg.): $15,500 per drop, $3.1MM total

Chameleon mini-I/O Drop 800 drops required Volume: 0.71 ft3 per drop, 571 ft3 total Weight: 16 lbs per drop, 12,800 lbs total Estimated Cost: $4,500 per drop, $3.6MM total


CVN-21 MCMS Example Plant

Example plant layout for I/O drop 100 points of I/O Ten pieces of machinery 100ft x 100ft plant All cabling runs to I/O drop Mix of analog and digital cables Assumed cable weights of

0.075lbs/ft and 0.1lbs/ft Estimated cable weight: 269lbs

5

10

1

2 3 4

6

7 8 9

I/O

Dro

p

0,0

100,0

0,100

100,100


CVN-21 MCMS Example Plant

Example plant layout for Mini I/O drop 100 points of I/O (4 mini drops) Ten pieces of machinery 100ft x 100ft plant Network cable runs to Mini I/O drops Assumed average power source

within 25ft Assumed average I/O length is 28ft Assumed CAT5e network cable

weight 0.065lbs/ft (LSC5OSW-4) Assumed I/O and power wire weights

of between 0.075lbs/ft and 0.1lbs/ft Estimated cable weight: 85lbs

5

10

1

2 3 4

6

7 8 9

0,0

100,0

0,100

100,100

Mini I/O Drop

Mini I/O Drop Mini I/O Drop

Mini I/O Drop


CVN-21 MCMS Mini I/O Benefits

Assume example platform has 200 plants similar to example plant (i.e. 20,000 points of I/O on platform)

Total Weight Comparison I/O drop weight

• Cable: 53,800 lbs• I/O Drops: 18,000 lbs• Total: 71,800 lbs

Mini I/O drop weight• Cable: 17,000 lbs• Mini I/O Drops: 12,800 lbs• Total: 29,800 lbs

Weight Savings: 42,000 lbs (over 18 tons or the 1.4 times the weight of one empty F/A-18F jet fighter!)


CVN-21 MCMS Mini I/O Benefits

Significant cabling reduction Cable cost savings Installation labor cost savings Design engineering cost savings (simplified drawings) Weight savings: 42,000 lbs

Simplified troubleshooting Easier to isolate wiring problems Can operate systems in isolation Don’t need to bring up all systems at once

Improved survivability Move towards decentralizing control

Heartbeat control Mode shedding


Chameleon Modules

AC Power Module (ACP-1, ACP-1PA) DC Power Module (DCP-1) Process Control Module (PCM-1) Discrete Automation Module (DAM-1, DAM-2) Network Interface Modules (NIM-1, NIM-3, NIM-4, NIM-6)

RS-485, RS-422, RS-232 Modbus LonTalk FairNET User-defined ASCII / Binary messaging

User Configurable Modules (UCM-1, UCM-2, UCM-2NB, UCM-2AMI)


AC/DC Power Modules

Single or Multi Power Source Redundant Power with Automatic

Switch-over Rugged packaging Spike Tolerance per MIL-STD 1399 Over-current Shut-off Input Circuit Fused ACP-1PA Standalone Power

Source


Process Control Module (PCM-1)

Process and Motion Control Four Analog Inputs

Current, Voltage, Resistance, RTD Four Analog Outputs

Current, Voltage Two Digital Inputs

On/Off, pulse counting Frequency meter, event timing Pulse width, quadrature decoding

Two Digital Outputs On/Off, PWM, square-wave generator

Four 4-digit numeric displays Eight 3-color LED indicators


Discrete Automation Module (DAM-2)

Discrete logic, sequence, batch Ten Digital Inputs

Broad range of AC or DC signals Configured in software

Eight Digital Outputs AC or DC Individually Soft-Configured Hybrid Mechanical / Solid-State Relays Dramatically improved endurance Drastically reduce conducted and radiated

EMI produced when switching inductive loads by maintaining zero voltage crossing turn on and zero current crossing turn off

Four Push-Buttons Eight 3-color LED indicators


Network Interface Modules

Network Media Available Today: NIM-1: RS-485, NIM-3: RS-422 NIM-4: RS-232, NIM-6: TP/FT10

Network Protocols Available Today: Modbus (Master/Slave, RTU/ASCII) LonTalk FairNET (FAC2000 Integration) OPC Server (ICAS Integration) Custom ASCII / Binary Protocols

NMEA Implementation Adaptable to custom TCP/IP messaging

Currently In Development NIM-2: Ethernet w/ 6-Port Switch NIM-5: Ethernet (TCP/IP, Ethernet/IP) NIM-7: ProfiBUS DP (Master/Slave)


User-Configurable Modules (UCM-X)

Custom modules with buttons, displays, etc. Use as junction box Available in full or half size


Development Roadmap

Networking Modules in Development: NIM-2: Ethernet with built-in 6-Port Switch NIM-5: Ethernet (support TCP/IP, Ethernet/IP, ProfiNET) NIM-7: ProfiBUS DP (Master/Slave) NRM-1: Multi-port RS-485 Repeater Module

Wireless Access Point Module Joint Development Program with 3e Technologies (SBIR) FIPS 140.2 Certified Wireless Security 802.11 a/b/g, Zigbee

Continue to Expand I/O Module Offering Touch-Screen Interface Module Motor Drive Module Battery Backup Module Direct connectivity to TSCE (DDS Protocol) Integrate C/C++ Programming with Function Blocks Plant-wide Configuration Management


Easy to Use Graphical Programming Intuitive Function Block Diagrams

Requires Little or No Training

State-Transition Diagrams Clear and Concise Method of Programming Reduced Program Size and Complexity Organizes Complex Control into Easy to Program Nuggets Eliminates Multiple Use of Interlocks and Transition Logic Typical Using

Ladder Logic

Integrated Simulation Platform All signal values continuously displayed during simulation run Simplifies Diagnostics and Check-out by Highlighting Active States

Wireless Device Configuration

PAC Programming: Design Pad G3


Design Pad G3 Demonstration

Documents

© 2005 Fairmount Automation, Inc. All Rights Reserved. Reduce Cost, Size, and Weight Programmable Automation Controllers (PAC) July 21, 2005