Interfacing Building
Automation Systems
(BAS) to Process Control
Presented by:
Gordon MacLachlan
(Mac)
Presentation Highlights

The Need for BAS In Process Control Systems

The Need for Process Control in BAS Systems

Common BAS Network Protocols

Common Process Control Network Protocols

FieldServer Protocol Support

FieldServer Hardware Solutions

Case Study: Interfacing with Rockwell

General Integration Considerations
The Need for BAS
in Process Control

Energy Management
• Process Control and BAS equipment interact to minimize
energy requirements
• Example: Different cooling schedules for a building when plant
is in or out of operation

Safety
• Process Control Events could trigger safety actions on the BAS
side and vice versa.
• Example: Gas leak detection could close room vents in
affected zone.

Centralized Control
• Centralized operations lead to the desire for homogenous host
HMI’s that monitor both BAS and Process control.
The Need for Process
Control in BAS

Optimized Environmental Control
• Control Process affect the building environment. Monitoring
the process allows for predictive zone management.

Shared technology
• BAS makes use of many of the same types of equipment that
Process Control does.
• Examples: Boilers, UPS systems, VFD’s etc.
Common BAS Networks

Open Protocol Networks
• BACnet
• LonWorks
• Modbus

Common OEM Networks
•
•
•
•

JCI Metasys N2
Data Aire
Carrier
Lutron
Fire Alarm Control Panel (FACP) Networks
•
•
•
•
•
Notifier
EST
Simplex
Siemens
Fike, and others
Common Process Control
Networks

Open Protocol Networks
•
•
•
•
•
•
•

Modbus/TCP
Modbus RTU
OPC
ODVA EtherNet/IP
DeviceNet
Profibus
Hart
Common OEM Networks
•
•
•
•
•
AB
AB
AB
GE
GE
CSP
DF1
ControlNet
SNP
SRTP
CASE STUDY:
Rockwell Interface
Deciding on a Protocol – Factors that count

Legacy PLC/SLC, or “Logix”?
• If ControlLogix, then use SlotServer

Is the serial DF1 port in use?
• If so, then rule out DF1 as an option

Does the specification state protocol to be used?
• If so, then decision is made

Cost of PLC equipment needed for the interface
• Price differences may be significant.

Client or Server Application?
• For HMI Interface, use OPC.
CASE STUDY:
Rockwell Interface
The ControlLogix Solution: SlotServer


Direct connection from Allen Bradley
ControlLogix PLC to another network
Standard 1756 format plugging
directly into the Allen Bradley
ControlLogix rack

RS-485 port for devices/networks
using RS-485 protocols

Ethernet port for Configuration
Utilities & Ethernet devices/network


LonWorks
TP/FT-10
interface
Standard LonWorks TP/FT-10
interface for LonWorks
devices/network
Installing the SlotServer module is a
very simple procedure
Ethernet port
RS-485 port
CASE STUDY:
Rockwell Interface
SlotServer Features



Plug the SlotServer directly into the
ControlLogix Communications rack
Scrolling text display with 3 status
LED’s provides card status at a
glance
A bank of six LED’s provides
communications status at a glance,
as well as additional diagnostic
indications

Ethernet port for advanced
troubleshooting purposes

Service Pin for LonWorks
commissioning
Diagnostic
displays
Service Pin
CASE STUDY:
Rockwell Interface
Hardware Specifications:

Backplane Load: 0.6A

Slot width: 1


Operating Temperature: -40 to 185
Deg. F
Humidity: 5-95% (non-condensing)
CASE STUDY:
Rockwell Interface
Software Features




Transfer up to 6000 points between
ControlLogix and many third party
interfaces.
Configure the SlotServer to
communicate with many different
protocols, including LonWorks,
BACnet, Metasys and Modbus.
Flexible configuration architecture
allows for creative connectivity
options.
Use the Standard SlotServer profiles
for connection without configuration
CASE STUDY:
Rockwell Interface
Software Features


Control communications in the
ControlLogix software using
standard generic message blocks
Example message block code
provided in an ACD file with the
SlotServer
CASE STUDY:
Rockwell Interface
Distinct Advantages SlotServer



Allows connection of a Third Party
Network to a ControlLogix system
without the use of external
gateways
Sits in the ControlLogix rack,
thereby preserving cabinet “Real
Estate”
Provides generic profiles (such as
LonWorks Open Interface) or
custom profiles (with configuration),
allowing for a choice between ease
and flexibility.
CASE STUDY:
Rockwell Interface
Generic vs Custom Mapping




SlotServer can ship default with generic open profile or can
be shipped as the configurable version.
The generic profile eliminates the need for messing with
config.csv, thus reducing commissioning time.
Creating a custom profile with config.csv allows for more
flexibility to suit the specific application
FieldServer offers custom profiling services if needed.
CASE STUDY:
Rockwell Interface
Preparing for Configuration
1.
2.
3.
4.
Training – Attend a FieldServer training class or order the
first SlotServer pre-configured as a template to learn from.
Input – Acquire information about BAS protocol points to
be mapped. Information must include point address details
for the particular protocol.
Draw – A picture paints the proverbial 1000 words.
Sketch a network diagram, and then sketch a schematic of
how the data blocks are to be mapped.
Configure – With the first 3 steps done correctly, this
step becomes easy.
CASE STUDY:
Rockwell Interface
SlotServer Data Transfer over IO Data Image
Logix CPU
SlotServer
Input Data Image
Controller Tag
Local:Slot:I:Data
External Device
eg. LonWorks
Modbus
Input Data
Metasys
In [0]
Input Data
Multiplexer
Offset Description
0
Protocol Type
1
Node Status
2
Data Block Number
3
Reserved
In [1]
In_1
In_2
In_3
In_4
..
In_25
In [24]
Data Arrays.
Map Third party
points into and
out of these
data arrays and
let the Logix
driver do the
rest.
4
Output Data Image
Controller Tag
In_x
Data
...
Output Data
79
Out [0]
Output Data
DeMultiplexer
Local:Slot:O:Data
Offset Description
0
Protocol Type
1
Node Status
2
Data Block Number
3
Reserved
Out_1
Out_2
Out_3
Out_4
..
Out_25
4
...
79
Out_x
Data
Out [1]
Out [24]
Multiple blocks
exist so that
the data can be
mapped
through the
limited IO
Buffer on the
backplane using
multiplexing.
CASE STUDY:
Rockwell Interface
Example: Connecting the SlotServer
to
LonWorks
Sample Mapping:
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.
Map_Descriptors
Map_Descriptor_Name, Data_Array_Name, Data_Array_Offset, Lon_Function, Function, Node_Name, SNVT_Type
nvoVolt1_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
Considerations

Are you a BAS expert or a Process Control expert?
• Bridging between industries probably means that the user will
be familiar with one side of the gateway application, but not
the other. Some familiarization with the unknown side will be
required.
General Integration
Considerations

Different Protocols behave differently
• LonWorks has binding, BACnet autodiscovers, EtherNet/IP
talks tags, Profibus needs gsd’s, whereas ControlNet needs
eds’s. Metasys has slaves, Modbus polls, GE EGD has
subscribers, etc, etc..
• The bottom line is they all do the same thing in different ways.
They all pass data.
• Configuring these protocols is typically easy due to tools
provided. However, knowing what to configure is not.
General Integration
Considerations

Scaleable support – Use what
you need
• Using a FieldServer product requires purchase,
configuration, commissioning and support
• If familiar with the network protocols involved
consider purchasing the product and doing
configuration and commissioning yourself
• If unfamiliar with the network protocols,
consider purchasing the configuration
• If unfamiliar with network integration,
consider purchasing the commissioning.
General Integration
Considerations

Getting it right – Input is the key
• GIGO – Garbage in, garbage out - GUARANTEED
• To configure a FieldServer product, details of the
data to be mapped is required. This is the
configuration input.
• The quality of the configuration input determines
the quality of the configuration, which in turn
determines the success of the commissioning
process.
• The bottom line: Spend more time getting the
input right.
Resources

FieldServer Website (www.FieldServer.com)

LonMark website (www.LonMark.org)

Modbus IDA website (www.modbus.org)

Echelon Website (www.echelon.com)

Rockwell Allen-Bradley Website (www.ab.com)

BACnet Website (www.bacnetinternational.com)

Rockwell Automation Encompass Website
(www.rockwellautomation.com/encompass/)
Contacts
Marketing and Sales:
Steve Ferree: sferree@fieldserver.com
Richard Theron: rtheron@fieldserver.com
Technical:
Mac: mac@sfintegration.com
THANK YOU!
…..for taking the time to attend this
presentation.
Questions?