Interfacing Building Automation Systems (BAS) to Process Control Presented by: Gordon MacLachlan (Mac)

Interfacing Building Interfacing Building Automation Systems Automation Systems

(BAS) to Process Control(BAS) to Process Control

Presented by:Presented by:

Gordon MacLachlan Gordon MacLachlan (Mac)(Mac)

Presentation HighlightsPresentation Highlights The Need for BAS In Process Control SystemsThe Need for BAS In Process Control Systems

The Need for Process Control in BAS SystemsThe Need for Process Control in BAS Systems

Common BAS Network ProtocolsCommon BAS Network Protocols

Common Process Control Network ProtocolsCommon Process Control Network Protocols

FieldServer Protocol SupportFieldServer Protocol Support

FieldServer Hardware SolutionsFieldServer Hardware Solutions

Case Study: Interfacing with RockwellCase Study: Interfacing with Rockwell

General Integration ConsiderationsGeneral Integration Considerations

The Need for BAS The Need for BAS in Process Controlin Process Control

Energy ManagementEnergy Management

• Process Control and BAS equipment interact to minimize Process Control and BAS equipment interact to minimize energy requirementsenergy requirements

• Example: Different cooling schedules for a building when plant Example: Different cooling schedules for a building when plant is in or out of operationis in or out of operation

SafetySafety

• Process Control Events could trigger safety actions on the BAS Process Control Events could trigger safety actions on the BAS side and vice versa.side and vice versa.

• Example: Gas leak detection could close room vents in Example: Gas leak detection could close room vents in affected zone.affected zone.

Centralized ControlCentralized Control

• Centralized operations lead to the desire for homogenous host Centralized operations lead to the desire for homogenous host HMI’s that monitor both BAS and Process control.HMI’s that monitor both BAS and Process control.

The Need for Process The Need for Process Control in BASControl in BAS

Optimized Environmental ControlOptimized Environmental Control

• Control Process affect the building environment. Monitoring the Control Process affect the building environment. Monitoring the process allows for predictive zone management.process allows for predictive zone management.

Shared technologyShared technology

• BAS makes use of many of the same types of equipment that BAS makes use of many of the same types of equipment that Process Control does.Process Control does.

• Examples: Boilers, UPS systems, VFD’s etc.Examples: Boilers, UPS systems, VFD’s etc.

Common BAS NetworksCommon BAS Networks Open Protocol NetworksOpen Protocol Networks

• BACnetBACnet• LonWorksLonWorks• ModbusModbus

Common OEM NetworksCommon OEM Networks• JCI Metasys N2JCI Metasys N2• Data AireData Aire• CarrierCarrier• LutronLutron

Fire Alarm Control Panel (FACP) NetworksFire Alarm Control Panel (FACP) Networks• NotifierNotifier• ESTEST• SimplexSimplex• SiemensSiemens• Fike, and othersFike, and others

Common Process Control Common Process Control NetworksNetworks

Open Protocol NetworksOpen Protocol Networks• Modbus/TCPModbus/TCP• Modbus RTUModbus RTU• OPCOPC• ODVA EtherNet/IPODVA EtherNet/IP• DeviceNetDeviceNet• ProfibusProfibus• HartHart

Common OEM NetworksCommon OEM Networks• AB CSPAB CSP• AB DF1AB DF1• AB ControlNetAB ControlNet• GE SNPGE SNP• GE SRTPGE SRTP

Deciding on a Protocol – Factors that countDeciding on a Protocol – Factors that count

Legacy PLC/SLC, or “Logix”?Legacy PLC/SLC, or “Logix”?• If ControlLogix, then use SlotServerIf ControlLogix, then use SlotServer

Is the serial DF1 port in use?Is the serial DF1 port in use?• If so, then rule out DF1 as an optionIf so, then rule out DF1 as an option

Does the specification state protocol to be used?Does the specification state protocol to be used?• If so, then decision is madeIf so, then decision is made

Cost of PLC equipment needed for the interfaceCost of PLC equipment needed for the interface• Price differences may be significant.Price differences may be significant.

Client or Server Application?Client or Server Application?• For HMI Interface, use OPC.For HMI Interface, use OPC.

CASE STUDY: CASE STUDY: Rockwell InterfaceRockwell Interface

Direct connection from Allen Bradley Direct connection from Allen Bradley ControlLogix PLC to another networkControlLogix PLC to another network

Standard 1756 format plugging Standard 1756 format plugging directly into the Allen Bradley directly into the Allen Bradley ControlLogix rackControlLogix rack

RS-485 port for devices/networks RS-485 port for devices/networks using RS-485 protocolsusing RS-485 protocols

Ethernet port for Configuration Ethernet port for Configuration Utilities & Ethernet devices/networkUtilities & Ethernet devices/network

Standard LonWorks TP/FT-10 interface Standard LonWorks TP/FT-10 interface for LonWorks devices/network for LonWorks devices/network

Installing the SlotServer module is a Installing the SlotServer module is a very simple procedurevery simple procedure

LonWorks TP/FT-10 interface

RS-485 portEthernet port


The ControlLogix Solution: SlotServerThe ControlLogix Solution: SlotServer

SlotServer FeaturesSlotServer Features

Plug the SlotServer directly into the Plug the SlotServer directly into the ControlLogix Communications rackControlLogix Communications rack

Scrolling text display with 3 status Scrolling text display with 3 status LED’s provides card status at a LED’s provides card status at a glanceglance

A bank of six LED’s provides A bank of six LED’s provides communications status at a glance, communications status at a glance, as well as additional diagnostic as well as additional diagnostic indicationsindications

Ethernet port for advanced Ethernet port for advanced troubleshooting purposestroubleshooting purposes

Service Pin for LonWorks Service Pin for LonWorks commissioningcommissioning

Diagnostic displays

Service Pin


Hardware Specifications:Hardware Specifications: Backplane Load: 0.6ABackplane Load: 0.6A

Slot width: 1Slot width: 1

Operating Temperature: -40 to 185 Operating Temperature: -40 to 185 Deg. FDeg. F

Humidity: 5-95% (non-condensing)Humidity: 5-95% (non-condensing)


Software FeaturesSoftware Features Transfer up to 6000 points between Transfer up to 6000 points between

ControlLogix and many third party ControlLogix and many third party interfaces.interfaces.

Configure the SlotServer to Configure the SlotServer to communicate with many different communicate with many different protocols, including LonWorks, protocols, including LonWorks, BACnet, Metasys and Modbus.BACnet, Metasys and Modbus.

Flexible configuration architecture Flexible configuration architecture allows for creative connectivity allows for creative connectivity options.options.

Use the Standard SlotServer profiles Use the Standard SlotServer profiles for connection without configuration for connection without configuration


Software FeaturesSoftware Features Control communications in the Control communications in the

ControlLogix software using ControlLogix software using standard generic message blocksstandard generic message blocks

Example message block code Example message block code provided in an ACD file with the provided in an ACD file with the SlotServerSlotServer


Distinct Advantages - Distinct Advantages - SlotServerSlotServer

Allows connection of a Third Party Allows connection of a Third Party Network to a ControlLogix system Network to a ControlLogix system without the use of external without the use of external gatewaysgateways

Sits in the ControlLogix rack, Sits in the ControlLogix rack, thereby preserving cabinet “Real thereby preserving cabinet “Real Estate”Estate”

Provides generic profiles (such as Provides generic profiles (such as LonWorks Open Interface) or custom LonWorks Open Interface) or custom profiles (with configuration), profiles (with configuration), allowing for a choice between ease allowing for a choice between ease and flexibility.and flexibility.


Generic vs Custom MappingGeneric vs Custom Mapping SlotServer can ship default with generic open profile or can SlotServer can ship default with generic open profile or can

be shipped as the configurable version.be shipped as the configurable version.

The generic profile eliminates the need for messing with The generic profile eliminates the need for messing with config.csv, thus reducing commissioning time.config.csv, thus reducing commissioning time.

Creating a custom profile with config.csv allows for more Creating a custom profile with config.csv allows for more flexibility to suit the specific applicationflexibility to suit the specific application

FieldServer offers custom profiling services if needed.FieldServer offers custom profiling services if needed.


Preparing for ConfigurationPreparing for Configuration

1.1. TrainingTraining – Attend a FieldServer training class or order the – Attend a FieldServer training class or order the first SlotServer pre-configured as a template to learn from.first SlotServer pre-configured as a template to learn from.

2.2. InputInput – Acquire information about BAS protocol points to – Acquire information about BAS protocol points to be mapped. Information must include point address details be mapped. Information must include point address details for the particular protocol.for the particular protocol.

3.3. DrawDraw – A picture paints the proverbial 1000 words. Sketch – A picture paints the proverbial 1000 words. Sketch a network diagram, and then sketch a schematic of how a network diagram, and then sketch a schematic of how the data blocks are to be mapped.the data blocks are to be mapped.

4.4. ConfigureConfigure – With the first 3 steps done correctly, this step – With the first 3 steps done correctly, this step becomes easy.becomes easy.


Local:Slot:I:Data

Local:Slot:O:Data

Input Data ImageController Tag

Output Data ImageController Tag

Logix CPU

Input Data Multiplexer

Output Data DeMultiplexer

SlotServerInput Data

In [24]

Out [24]

Out [0]

External Deviceeg. LonWorks

ModbusMetasys

0

1

2

3

4

...

79

Protocol Type

Node Status

Data Block Number

Reserved

In_xData

Out_xData

Offset Description

SlotServer Data Transfer over IO Data Image

In [1]

Offset Description

In [0]

0

1

2

3

4

...

79

Protocol Type

Node Status

Data Block Number

Reserved

Output Data

Out [1]

In_1In_2In_3In_4..In_25

Out_1Out_2Out_3Out_4..Out_25

Data Arrays.

Map Third party points into and

out of these data arrays and let

the Logix driver do the rest.

Multiple blocks exist so that the

data can be mapped through

the limited IO Buffer on the

backplane using multiplexing.


Example: Connecting the SlotServer Example: Connecting the SlotServer to LonWorksto LonWorks

Sample Mapping:Sample Mapping:

The points below show a sample of Lon Points that are mapped into the The points below show a sample of Lon Points that are mapped into the Data Arrays that get multiplexed in and out of the Backplane buffers.Data Arrays that get multiplexed in and out of the Backplane buffers.

Map_DescriptorsMap_Descriptor_Name, Data_Array_Name, Data_Array_Offset, Lon_Function, Function, Node_Name, SNVT_TypenvoVolt1_25 ,Out_25 ,74 ,NVUOIMX ,WRBX ,Lon_Srv_1 ,SNVT_volt nvoVolt2_25 ,Out_25 ,75 ,NVUOIMX ,WRBX ,Lon_Srv_1 ,SNVT_volt nviAmp1_01 ,In_1 ,00 ,NVUI ,Server ,Lon_Srv_1 ,SNVT_amp nviAmp2_01 ,In_1 ,01 ,NVUI ,Server ,Lon_Srv_1 ,SNVT_amp

Data Arrays Assigned to I/O Buffers by Logix

driver

Standard LonWorks Driver

Mapping


General Integration General Integration ConsiderationsConsiderations

Are you a BAS expert or a Process Control expert?Are you a BAS expert or a Process Control expert?

• Bridging between industries probably means that the user will Bridging between industries probably means that the user will be familiar with one side of the gateway application, but not be familiar with one side of the gateway application, but not the other. Some familiarization with the unknown side will be the other. Some familiarization with the unknown side will be required.required.


Different Protocols behave differentlyDifferent Protocols behave differently

• LonWorks has binding, BACnet autodiscovers, EtherNet/IP talks LonWorks has binding, BACnet autodiscovers, EtherNet/IP talks tags, Profibus needs gsd’s, whereas ControlNet needs eds’s. tags, Profibus needs gsd’s, whereas ControlNet needs eds’s. Metasys has slaves, Modbus polls, GE EGD has subscribers, Metasys has slaves, Modbus polls, GE EGD has subscribers, etc, etc..etc, etc..

• The bottom line is they all do the same thing in different ways. The bottom line is they all do the same thing in different ways. They all pass data.They all pass data.

• Configuring these protocols is typically easy due to tools Configuring these protocols is typically easy due to tools provided. However, knowing what to configure is not.provided. However, knowing what to configure is not.


Scaleable support – Use what Scaleable support – Use what you needyou need

• Using a FieldServer product requires purchase, Using a FieldServer product requires purchase, configuration, commissioning and supportconfiguration, commissioning and support

• If familiar with the network protocols involved If familiar with the network protocols involved consider purchasing the product and doing consider purchasing the product and doing configuration and commissioning yourselfconfiguration and commissioning yourself

• If unfamiliar with the network protocols, If unfamiliar with the network protocols, consider purchasing the configurationconsider purchasing the configuration

• If unfamiliar with network integration, consider If unfamiliar with network integration, consider purchasing the commissioning.purchasing the commissioning.


Getting it right – Input is the keyGetting it right – Input is the key

• GIGO – Garbage in, garbage out - GUARANTEEDGIGO – Garbage in, garbage out - GUARANTEED

• To configure a FieldServer product, details of the To configure a FieldServer product, details of the data to be mapped is required. This is the data to be mapped is required. This is the configuration input.configuration input.

• The quality of the configuration input determines The quality of the configuration input determines the quality of the configuration, which in turn the quality of the configuration, which in turn determines the success of the commissioning determines the success of the commissioning process.process.

• The bottom line: Spend more time getting the The bottom line: Spend more time getting the input right.input right.

ResourcesResources

FieldServer Website (www.FieldServer.com)FieldServer Website (www.FieldServer.com)

LonMark website (www.LonMark.org)LonMark website (www.LonMark.org)

Modbus IDA website (www.modbus.org)Modbus IDA website (www.modbus.org)

Echelon Website (www.echelon.com)Echelon Website (www.echelon.com)

Rockwell Allen-Bradley Website (www.ab.com)Rockwell Allen-Bradley Website (www.ab.com)

BACnet Website (www.bacnetinternational.com)BACnet Website (www.bacnetinternational.com)

Rockwell Automation Encompass Website Rockwell Automation Encompass Website (www.rockwellautomation.com/encompass/)(www.rockwellautomation.com/encompass/)

ContactsContacts

Marketing and Sales:Marketing and Sales:

Steve Ferree: [email protected] Ferree: [email protected]

Richard Theron: [email protected] Theron: [email protected]

Technical:Technical:

Mac: [email protected]: [email protected]

THANK YOU!THANK YOU!

……..for taking the time to attend this ..for taking the time to attend this presentation.presentation.

Questions?Questions?

Documents

Interfacing Building Automation Systems (BAS) to Process Control Presented by: Gordon MacLachlan (Mac)