Scalable Energy Efficient HMIs for Intelligent Building Automation Systems

Building Automation Management Solution Provider and BMS Training Provider

Known for their energy efficient, open platform and flexible building control and monitoring solutions, American Industrial Systems, Inc. (AIS), introduces their standard and custom offering of HMI panels for the building automation industry.

Known for their energy efficient, open platform and flexible building control and monitoring solutions, American Industrial Systems, Inc. (AIS), introduces their standard and custom offering of HMI panels for the building automation industry.  AIS open and flexible building control and monitoring solutions are designed for commercial and industrial facilities. By controlling building automation systems and simplifying operator interaction and engagement, AIS HMIs help building owners and operators manage their Building Management Systems (BMS), Energy Management Systems (EMS) and Building Automation Systems (BAS) more cost-effectively.  Building control systems applications suited for AIS HMI building management panels include: chiller control, boiler control, lighting control, HVAC control and access control systems.

In commercial buildings, the BMS is a computer-based control system installed in buildings that controls and monitors the building’s mechanical and electrical equipment. An EMS has software and data acquisition hardware components that are used to collect and analyze energy usage at the building or system level, mainly for monitoring decisions only. The BAS consists of stand-alone or networked hardware and embedded software that automatically controls a single building function (mechanical, electrical, or electronic).

AIS’s HMI Building Management Panels Solve Energy Challenges for Smart Building Operators

The building automation industry was an early innovator and adopter of the green movement in addressing environmental issues, reducing carbon emissions and energy costs.  Building and facilities operator embrace the need for continued energy management and sustainability.  BAS and BMS data from commercial buildings are new high-value assets and a major focus in managing energy consumption, triggered by rising energy costs, the benefits of proactive system maintenance and the need for remote property monitoring. AIS’s scalable and flexible operator interface panels deliver HMI integration and visualization of automation systems for smart buildings. Open platform HMI panels with pre-installed Windows embedded operating system from AIS offer hardware and software functional expansion capabilities with software development kits (SDK) for customer-specific applications. AIS building control management HMI panels and operator interfaces offer many benefits, including:

·       Powerful control, monitoring and targeting of energy consumption

·       Computerized and efficient maintenance scheduling

·       Effective use of maintenance staff and increased productivity

·       Reduced maintenance and energy costs

·       Remote monitoring and diagnostics of buildings and facilities

AIS’s Extensive Portfolio of Open & Rugged HMI Systems for Building Automation Control
AIS offers a broad range of flexible and versatile HMI panels and operator interface solutions for smart building control and automation systems that deliver the lowest total cost of ownership for building and facilities operators. Easy-to-use interfaces with advanced visualization capabilities and open communications platforms, AIS HMI panels are also rugged and can endure extreme conditions in HVAC environments and applications. The portfolio of HMI, operator interface terminals and touch panel PCs solutions for building control and management from AIS include:

·       Wide Temperature Touch Panel PCs feature Intel® Atom dual core processor N2800 1.86 GHz, in an industrial-grade LCD flat panel with resistive touch screen technology, and supports an extended temperature range of -20 to 60°C (-4 to 140°F). This selection of industrial and building automation displays are offered in screen sizes 10.4", 15" and 17".

·       HMI Operator Interface Terminals are web-based and ARM-based HMI solutions and one of the most versatile operator interface choices for visualization applications. They are ideal for building control applications that need information displayed in dynamic ways to help operators quickly understand machine status and make faster decisions. The displays for intelligent building automation are offered in sizes ranging from 4.3" to 15".

·       HMI Compact Thin Clients are compact web-based thin clients for faster, better and lower-cost building and HVAC applications. As standard, AIS HMI Compact Thin Clients for building control are ruggedized, and carry NEMA 12, 4X, 4, IP52, IP54, IP66 ratings and certifications. These smart building HMI displays are offered in 5.7", 10.1" and 15" size screens.

·  HMI PoE Touch Panel PCs are fully integrated, utilizing the very latest in Projective Capacitive Touch display (PCT) technology and Power-Over-Ethernet (PoE) capability in industrial-grade LCD panels. As the need for end devices continue to expand for communications, collaboration, security and productivity, the need for PoE capabilities to support these end devices with increased power requirements is essential. These smart, Multi-Touch “Room Scheduling” Panel PCs are offered in 7", 10.1” and 18.5" size screens.

ABB and Hitachi Form HVDC Partnership for Japan’s Power Grid

With Hitachi as the prime contractor, the joint venture will take ABB’s direct current technology into Japan’s evolving HVDC market.

By Aaron Hand, Executive Editor, Automation World

Swiss power and automation giant ABB has teamed up with Hitachi to gain a foothold in Japan’s high-voltage direct current (HVDC) market. The two companies have agreed to form a Tokyo-based joint venture that will be supply DC systems and services in Japan, with Hitachi as the prime contractor.

In the first step of a strategic partnership aimed at Japan's evolving power network, Hitachi will have an equity interest of 51 percent, and ABB will have the remaining 49 percent. The two companies will continue to explore the relationship further, looking to widen the scope for future collaboration.
“Since the first development in the 1970s,

Hitachi has participated in every HVDC project in Japan and has continued to underpin the stabilization of the electricity grid,” said Hiroaki Nakanishi, Hitachi’s chairman and CEO. “I am confident that the establishment of a new company combining the strengths of Hitachi and ABB will provide a framework for the timely provision of the new technologies required by the Japanese HVDC market. By enhancing and expanding the HVDC business through its partnership with ABB, which has a strong performance record in the global market, Hitachi will continue to contribute to the stabilization of Japan's electric power grid.”

Ulrich Spiesshofer, CEO of ABB, pointed to ABB’s pioneering role in HVDC 60 years ago. “Our presence across half the world’s installed base and our capability to develop and manufacture all major components of the HVDC value chain in-house have put us in a leading position in the industry,” he said. “We are proud to enter into this partnership with Hitachi, with a solid reputation and extensive, 100-year experience in the Japanese market. Together we can build on our complementary strengths to play our part in the evolution of Japan’s power infrastructure."

The global HVDC market has been dominated by line commutated converter (LCC) technology since the 1970s. But more recent focus on HVDC to connect renewable energy sources has seen an increase in voltage source converter (VSC) systems, which advanced as a new technology around 2000, and facilitate grid stabilization.

VSC-HVDC technology is suited to long-distance underground and underwater power links and interconnections, and is increasingly being deployed across a range of applications. These include the integration of renewable energies from land-based and offshore wind farms, the mainland power supply to islands and offshore oil and gas platforms, city center in-feeds where space is a major constraint, and cross-border interconnections that often require subsea links. Its ability to comply with grid codes ensures robust network connections regardless of application.

In Japan, nine HVDC projects were carried out up to 2006, all of them using the LCC technology. Now, with the increasing introduction of renewable energy and innovation in electric power systems, demand for VSC-HVDC systems is expected to increase for applications such as wide-area power transmission grids and connection of offshore wind farms.

The new joint venture will combine Hitachi's sales network, project management expertise, quality assurance processes and delivery performance record with ABB’s state-of-the-art HVDC technologies, and contribute to innovation in electric power systems in Japan.


Source:-http://www.automationworld.com/power-supplies/abb-and-hitachi-form-hvdc-partnership-japans-power-grid

Siemens Launches Optimized Servo Drive System for Motion Control Applications

Cost effective and easy-to-use, SINAMICS V90 servo drive and SIMOTICS S-1FL6 servo motor together form an optimized servo-drive system. Addresses a wide range of applications such as pick & place, labeling, horizontal packaging and printing.

Sofcon Providing Industrial Automation Training with 100% Placement Assistance.

Siemens Industry launched the newly-developed SINAMICS V90 servo drive and SIMOTICS S-1FL6 servo motor for motion control applications. The drive and the motor, together form an optimized servo drive system for positioning, speed and torque control. It not only provides a cost-effective solution but also shortens time-to-market with easy commissioning, thus improving customers’ competitiveness.

Cost-effective

Being a cost-effective product, SINAMICS V90 has various integrated control modes to address a wide range of applications such as pick & place, labeling, horizontal packaging, printing etc. It also finds use in winders and unwinders and automatic assembly machines. Point-to-point positioning is possible by using a basic PLC without a positioning functionality. With integrated braking resistor for all frame sizes, most applications can be realized without an additional braking resistor.

Optimized servo performance

SINAMICS V90 enables the machine to achieve a high dynamic performance and smooth operation through automatically optimized control loop parameters. Presence of 1 MHz pulse train setpoint and 20-bit encoder resolution enables the system to reach high positioning accuracy. The 300% overload capacity of the drive and motor along with fast acceleration and braking ensures high productivity for customers’ machines.

Easy to use

SINAMICS V-Assistant, an optimized, standalone, graphic configuration software tool makes commissioning and diagnostics quick and easy. This tool performs parameter settings, jogging, trouble shooting and monitoring. Standard interface makes it easy to couple the drive with PLCs and motion controllers.

Reliable operation

PCB coating on the SINAMICS V90 and high quality bearings of SIMOTICS S-1FL6 ensures a high robustness of the drive system, thus enabling them to withstand harsh environmental conditions. The integrated safety function STO (safe toque off) prevents the motor from unexpected movement; thereby ensuring safety of both machines and employees.

SINAMICS and SIMOTICS form an integral part of Siemens Integrated Drive Systems. Drive Technology based on Integrated Drive Systems ensures maximum productivity, energy-efficiency, and reliability in any automation environment and throughout the lifecycle.

The Future of Factory Automation | Industrial Automation Training at Sofcon

The concept of Factory Automation started in 1986 and dealt primarily with the automation of manufacturing, quality control and material handling processes. The idea was to employ automation to save up on the labor cost, reduce human error, save energy and materials and to improve quality, accuracy and precision. Various concepts & technologies like DCS, PLC, Industrial PC, Computer Numeric Control Network, Wireless sensor networks, Industrial Ethernet etc. have emerged and evolved over the years.

 

In today’s world, in order to remain competitive and thrive, many businesses are increasingly turning to advanced industrial automation to maximize productivity, economies of scale and quality. The increasingly connected world is inevitably connecting the factory floors. Human machine interfaces (HMI), Programmable logic controllers (PLC), Motor control and sensors need to be connected in a scalable and efficient way. The Internet of Things (IoT) is enabling machines and the automation systems to securely connect to each other, in an enterprise and to the rest of the supply chain and offer information that can be used for operative and analytical purposes.

Market & Trends

The global industrial automation market is forecasted to reach more than $200 billion by 2015, buoyed by improved economies worldwide. Purchased largely for manufacturing processes, industrial automation equipment is a key factor in a country’s gross domestic product (GDP) and, as IMS Research notes, generally indicative of economic health. As per a survey conducted by Frost & Sullivan, BRIC (Brazil, Russia, India and China) along with other emerging economies worldwide are forecast to sustain high growth in industrial automation markets. The strongest growth is expected in emerging markets, particularly in the Middle East, Southeast Asia and Eastern Europe. However, in more developed regions like North America and Western Europe, opportunities exist in the modernization of old infrastructure.

The biggest change to the factory of the future will come from technology. Future factories in the pursuit of sustainability, productivity & efficiency are adopting Factory Automation which will enable a truly integrated enterprise. Advanced controls, automation systems, and sensors are being used to improve industrial process control and energy efficiency in industrial settings. Whether reducing energy consumption or monitoring equipment for maintenance purposes, sensors, and wireless controls provide real-time data and the ability to configure and control plant related functions. The Integrated enterprise provides for an effective interaction between the factory floor and the enterprise across all end users, enabling organizations to gain a competitive edge in the global market. The organizations are also leveraging the benefits of IoT (Internet of Things) to connect data-driven devices to optimize their operations and improve decision making thus impacting revenues & profitability.

As per the latest report from IHS Technology on Industrial Automation Equipments, Motors and motor controls will be the largest segment in 2014, accounting for 40 percent of total IAE market revenue. Automation equipment is next with 31 percent, followed by power-transmission equipment with 29 percent. In the market’s biggest segment made up of motors, generators, and motor controls, energy efficiency continues to be the driver for growth and is a key care about.

One such Industry forum is the Industrial Energy Efficiency Coalition (IEEC) which is an alliance of leading Industrial organizations seeking to leverage their expertise and track record in industrial controls and automation to promote continuous energy efficiency improvements in industrial systems and processes, as well as business ecosystems.

The Anatomy of Factory Automation

Factory Automation constitute of five major components - PLC (Programmable Logic Controllers), HMI (Human Machine Interface) , Sensor,  Motor Control / Drives which are interconnected by Industrial communication protocols.

• PLC is the brain of an industrial automation system; it provides relay control, motion control, industrial input and output process control, distributed system, and networking control. PLCs often need to work in harsh environmental conditions, withstanding heat, cold, moisture, vibration and other extreme conditions while providing precise, deterministic and real-time controls to the other parts of the industrial automation system through reliable communication links.

• HMI is the graphical user interface for industrial control. It provides a command input and feedback output interface for controlling the industrial machinery. An HMI is connected through common communication links to other parts of industrial systems.

• Industrial drives are motor controllers used for controlling optimal motor operation. They are used in a very diverse range of industrial applications and come with a wide range of voltage and power levels. Industrial drives include but are not limited to AC and DC drives as well as servo drives that use a motor feedback system to control and adjust the behavior and performance of servo mechanisms.

• Sensors are the hands and legs of the industrial automation system that monitor the industrial operation conditions, inspections, measurements, and more, in real time.  A sensor in the industrial environment is either continuously or periodically measuring vital parameters such as temperature, pressure, flow, etc. Monitoring and maintaining process variables at the appropriate levels is extremely critical in industrial automation and process control. They are an integral part of industrial automation systems and provide trigger point and feedback for system control.

• Communication is the backbone of all the industrial components for efficient automation. The most common being Industrial Ethernet and Fieldbus communication protocols with master and slave functionality including EtherCAT®, Ethernet/IP, PROFIBUS®, PROFINET®, POWERLINK and SERCOS III. Wireless connectivity holds enormous promises for advance factory automation. Zigbee, Sub 1-GHz Smart Mesh, 6LoWPAN, ANT+ and evolving standards are enabling machines and the automation systems to securely connect to each other, in an enterprise and to the rest of the supply chain.

System Requirements

In today's factory automation market, new technology brings opportunities for industrial system developers to successfully address new challenges where systems require technologies to meet stringent requirements for high reliability in mission-critical environments. The success of an advance factory automation system design depends on few key factors.

Semiconductor Portfolio specific –

• Specialized product portfolio for Harsh Environments.
• Reliable and efficient communication network that connects all the components of the factory to work together effectively.
• Energy Efficiency is also a must have from a sustainability perspective.
• Long product life supply policy.
• Flexible and future-proof embedded processors.
• Solutions that meet industry safety needs (IEC61508, SIL)
• Space efficient solutions.

System specific –

• The primary challenge of sensing in industrial environments is conditioning low signal levels in the presence of high noise and high-surge voltage.
• Industrial-specific reference design and development tools.
• Production-ready comprehensive software, including communication protocols and signal chain solution.

Automation applications range from programmable logic controllers and industrial computers to human machine interface and industrial peripherals and drives. Texas Instruments is a global supplier with a broad selection of the right products and tools the complete and optimize the Industrial Automation system. TI Technology brings many new opportunities to industrial automation system developers, successfully addressing design challenges like providing high reliability products to support stringent manufacturer requirements needed for harsh environments, long product life supply policy, products optimized for industrial environments, reference design, software libraries.

The Works

Texas Instruments has a strategic commitment to the industrial automation industry, providing an extensive and reliable solution set - ranging from robust microcontrollers and ARM®-based microprocessors and wireless transceivers, complemented by a rich portfolio of analog IC's for power management, data converters, interfaces, amplifiers, industrial drivers. TI’s cutting-edge semiconductor manufacturing processes provide industrial designers with products that meet the highest standards and that are optimized for industrial environments and extend product life cycles.

Apart from the broad portfolio, TI has a rich suite of reference designs that have been introduced along with documentation on BOM, design files & test reports. There are currently 86 reference designs under the Factory Automation theme, developed by system experts in TI, targeting PLC, HMI, Machine vision, Field Transmitter & Process instrumentation & others. An example is the TI reference design targeting analog and digital I/O modules as well as power supply boards for Programmable Logic Controllers (PLCs). These boards are designed with consideration for special needs encountered with testing for EMC and surge requirements as described in industry standards like IEC61000-4. All boards undergo rigorous testing and come with full documentation, test results, design files and necessary firmware. These designs make it very easy to evaluate complete signal chain performance and help reduce time to market.

The benefits of TI's system-optimized products are immediate product availability, tools, software and hardware that ease and accelerate design time - plus the added reliability of a worldwide supplier with local expertise and support.

On the communication front, developers can get to market faster with the low-power ARM Cortex-A8 microprocessor family to incorporate multiple industrial communication protocols on a single chip. TI provides production-ready industrial Ethernet and Fieldbus communication protocols with master and slave functionality including: EtherCAT®, Ethernet/IP, PROFIBUS®, PROFINET®, POWERLINK and SERCOS III.  WiFi capability can be enabled with easy development on the IoT ready portfolio with flexible connection options, cloud support and on-chip Wi-Fi, Internet and robust security protocols.

Source:-http://www.aandctoday.com/technical-article/318-the-future-of-factory-automation

HANNOVER MESSE Showcases Latest Generation of Industrial Robots

Robotics Training at Sofcon India Pvt Ltd

Hannover. The world is at the dawn of a new age in industrial robotics. While industrial robots are mostly still large, heavy items of plant designed to rapidly process repetitive tasks from behind safety barriers in big factories, they are now also making their way into smaller factories, where they are more compact and versatile and are able to work alongside their human “co-workers” without any safety barriers. This proliferation of new application areas, coupled with burgeoning worldwide demand, is driving strong growth in robotics sales. The International Federation of Robotics (IFR) reports that its members sold around 170,000 industrial robots in 2013, an increase of 12 percent on 2012, and that 2014 is headed for similar growth.

With such a lot happening in the robotics industry, it is imperative that factory owners keep up to date with the latest developments. And there’s no better place to do this than in Hannover, Germany. Marc Siemering, Deutsche Messe’s Senior Vice-President responsible for HANNOVER MESSE: “At HANNOVER MESSE 2015, the world’s leading robot manufacturers will demonstrate that robotics is the key to enhanced competitiveness and flexibility in industrial production. Big names like Fanuc, Güdel and Kuka will be showcasing the latest generation of robots and highlighting the key role played by robotics in the fourth industrial revolution.”

Fanuc will be presenting its latest robotics and control/servo-drive solutions in what will be its first appearance at HANNOVER MESSE since 2003. “We will make extensive use of the fair to profile our multidisciplinary robotics and factory automation technologies,” said Fanuc Germany CEO Olaf Kramm.

Fanuc, Güdel and Kuka will be presenting their products and solutions at HANNOVER MESSE’s Industrial Automation show, as will Comau, Kawasaki, Stäubli, Mitsubishi, Epson, IBG, ABB and several other leading providers of robot-assisted automation technology. Among the innovations on show will be robots that are wonderfully simple to program and feature intuitive touchpad control technology. There will be robots that are capable of taking on a much greater range of tasks than conventional machines thanks to the latest sensor technology. 

ABB, of instance, will be launching YuMi, a two-armed collaborative assembly assistant that can see and feel its way around. Its soft, padded arms ensure that it can interact safely with its human counterparts. Siemering: “These latest robots give factories the flexibility to accommodate today’s steadily growing demand for customer individualization in series production. They are also much more affordable and simpler to program, which puts them within reach of small and medium enterprises.”

The exhibition area at Industrial Automation will be supported by an array of amazing special displays and shows. At the Robotics, Automation & Vision display area, for example, system integrators will demonstrate their applications and solutions for robot-assisted automation in a range of industries. Mobile Robots & Autonomous Systems is another must-see special display. It will feature the latest technologies and innovations in mobile industrial and service robotics.

2015 will also be the fifth time that the ROBOTICS AWARD is offered by the organizers of HANNOVER MESSE. The Award honors companies that develop products, projects and technological advancements that make an innovative contribution to robotics-based solutions in the areas of industrial automation, mobile robots and autonomous systems. Olaf Lies, the Lower Saxony Minister for Economics, Labor and Transportation, with present the winners with their prizes at a special ceremony at the Automation Forum on 14 April 2015.

But before then, there’s the 4th ROBOTICS CONGRESS, which will be held in Hannover on Tuesday 9 December 2014 and will explore current trends in applied robotics. Among the discussion topics will be the move towards robots which are easy to operate and integrate and hence open up new areas of application. One such area is human-machine collaboration – as reflected in the congress’s lead theme of “Human-Robot Collaboration.” The program includes technical presentations and discussions, not to mention keynotes from such notables as Dr. Norbert Elkmann, Director Robot Systems, Fraunhofer Institute for Factory Operation and Automation (Fraunhofer IFF). Dr. Elkmann’s address is titled “Safe Human-Machine Collaboration – Current Developments and Projects.” The congress will be held in the Convention Center (CC) at the Hannover Exhibition Center.

HANNOVER MESSE – Get new technology first!

The world’s leading trade fair for industrial technology is staged annually in Hannover, Germany. The next HANNOVER MESSE will run from 13 to 17 April 2015 and feature India as its official Partner Country. HANNOVER MESSE 2015 will comprise ten flagship fairs: Industrial Automation • Motion, Drive & Automation (MDA) • Energy • Wind • MobiliTec • Digital Factory • ComVac • Industrial Supply • Surface Technology • Research & Technology. The upcoming event will place a strong emphasis on Industrial Automation and IT, Power Transmission and control, Energy and Environmental Technologies, Industrial Subcontracting, Production Engineering and Services and Research & Development.

About Deutsche Messe AG : 

With revenue of 312 million euros (2013), Deutsche Messe AG ranks among the world’s ten largest trade fair companies and operates the world’s largest exhibition center. In 2013, Deutsche Messe planned and staged 119 trade fairs and congresses around the world – events which hosted a total of 41,000 exhibitors and some four million visitors. The company’s event portfolio includes such world-leading trade fairs as CeBIT (IT and telecommunications), HANNOVER MESSE (industrial technology), BIOTECHNICA (biotechnology), CeMAT (intralogistics), didacta (education), DOMOTEX (floor coverings), INTERSCHUTZ (fire prevention and rescue), and LIGNA (wood processing and forestry). With over 1,000 employees and a network of 66 representatives, subsidiaries and branch offices, Deutsche Messe is present in more than 100 countries worldwide.



Source:-http://www.aandctoday.com/newsline/312-hannover-messe-showcases-latest-generation-of-industrial-robots

Aplus Finetek announces EST Grain Temperature/Level Monitoring System

Temperature/Level Monitoring System for use in monitoring grain quality in storage through multiple point temperature measurement within each grain bin.  The product line consists of two sensor cable types, the EST110 temperature monitoring cable and the EST120 temperature/level monitoring cables.  Each use sensing technology to minimize installation costs and maximize performance and value.  Readout via PC-software and a future wall-mounted graphic display/keypad interface.

Monitoring grain temperatures throughout storage bins is an important function to maintain adequate grain quality by detecting insect infestation and mold growth.  The EST110 grain temperature monitoring cables use simple high performance 1-wire digital temperature sensors that can be located at multiple points within a single cable of overall length up to 98.5ft (30m).  The use of these digital sensors simplifies installation as only a single pair of wire is needed from each multiple point temperature cable.  Each cable will connect locally at each bin to our HubLink data processor which provides an easily installed RS485 MODBUS 2-wire connection into the system.  Multiple HubLink units can be daisy-chained with a single 2-wire cable to the PC or operator interface.  Aplus Finetek’s MMS-TLA Series software provides the graphic interface to the entire system.

The EST120 combines multiple point temperature sensing using 1-wire digital sensors with continuous capacitance level measurement to provide an RS485 MODBUS connection into the system with or without HubLink units to the MMS-TLA PC software or the future RCU graphic wall-mounted interface.



Source:-http://www.automation.com/automation-news/aplus-finetek-announces-est-grain-temperaturelevel-monitoring-system

IEC 61131-3-Based Building Automation System

By Bill Lydon, Editor

Beckhoff Automation’s new $8 millionUSA headquarters features a building automation system (BAS) based on Beckhoff‘s own hardware, TwinCAT software, and IEC-61131-3 control logic. The new 44,500 square foot building in Savage, Minnesota opened in May 2013.  During their open house, I toured and reviewed the building automation system with Sree Swarna Potluri, Beckhoff Application Engineer, who was a key team member in the design and implementation of the system.
Potluri explained that the Beckhoff hardware and software provided the ability to freely implement any functions required for the BAS for initial project.  There is also complete flexibility for future enhancements. The system was implemented using Beckhoff’s programmable controllers and software based on IEC 61131-3 and a standard library of building automation functions including lighting control, window shade control, climate control, and energy consumption monitoring. The BAS uses BACnet communication as its backbone plus interfaces to other commonly-used building automation subsystems.

The building is served by seven rooftop units and boilers for hot water heating. Four of the rooftops units serve the warehouse area by supplying air-conditioning and heating. The other three rooftop units (air conditioning only) serve the balance of the building. That same balance of the building is heated with hot water heating coils served by dual boilers with redundant circulating pumps. Potluri explained that each boiler can handle 75% of ‘worst case’ heating design requirements in the event that one fails – an important factor during Minnesota winters.

The building has a weather station on the roof which communicates with the controllers using the Modbus RTU protocol to automatically make temperature adjustments, optimizing HVAC efficiency. The actuators on the Variable Air Volume (VAV) boxes are controlled directly from Beckhoff controllers over the Belimo MP-Bus network interface.

Potluri implemented a hot water reset on the boilers based on outdoor temperature and value positions at the heating coils to optimize energy. Nighttime sub-cooling is used in the summer season to take advantage of off-peak electric rates. Building ventilation control is optimized for occupancy based on input from CO² sensors.

Lighting Control:-

The system provides adaptive lighting control for daylight harvesting based on outside natural lighting, time of day schedules, automated window shades, and motion sensors to determine room occupancy. The motion sensors and lighting fixtures are interfaced directly to the Beckhoff controllers using the DALI (Digital Addressable Lighting Interface) communications network. In this configuration, the Beckhoff controllers are the DALI masters providing fully programmable lighting control.

Sun Blinds:-

The building incorporates automated window blinds for glare control and to reduce heat gain in cooling seasons. Blinds are controlled based on sun position and radiation information from the building’s weather station. The use of automated window blinds is common in other parts of the world and is starting to be implemented in leading new building designs in the United States.

Maintenance:-

The Beckhoff BAS monitors and sends alarms for maintenance information including exceeding runtime limits and faults. Users can be notified with alarms directly on a computer, via email or other means.

User Interface:-

The system can be accessed by any computer that is on the building’s Ethernet network or remotely through the Internet, provided the user has the correct password access rights. The building has Beckhoff CP6607 displays built into walls so occupants (with access privileges) can control functions including lighting, blinds, and temperature. The Beckhoff CP6607 is a panel PC with a 5.7-inch display, 640 x 480 pixel VGA resolution, Compact Flash card slot and a Mini PCI slot.

Wall mounted touch screen computers make it easy to make changes for special situations such as off hour meetings.

Controllers:-

The controllers for the system are three Beckhoff CX5020 Embedded PCs running Windows XP Embedded.  The PC incorporate a 1.6 GHz Intel® Atom™ Z530 processor that supports hyper threading technology with two virtual CPU cores for more effective execution of software. A key to this application is the freedom to control all aspects of the control program using IEC 6 1131-3.

Beckhoff CX5020 Embedded PC controllers communicate on BACnet mounted in field cabinet with I/O and interfaces to DALI and MP-Bus networks.

After the tour, Potluri introduced Beckhoff’s new BC9191 Building Automation Room Controller which was designed specifically for building automation projects. Unfortunately, the controller was not released in time for use on this project. The BC9191 has dual switched Ethernet ports, RS-485 sub-bus, and the following onboard I/O:

• 3 Digital contact inputs
• 3 Analog Inputs 0-10 volt
• 1 Pt/Ni1000 Analog Input
• 1 Digital 230 VAC, 10 A, relay output
• 3 Relay Outputs 230 VAC, 1 Amp
• 2 Triac Outputs 230 V AC, 1 A
• 2 Analog outputs, 0…10 V

The BC9191 controller also can accommodate additional I/O expansion using Beckhoff I/O modules for a wide range of I/O and interfaces including EnOcean technology, MP-Bus master, DALI/DSI master and power supply, M-Bus master, LON Bus Terminal, and 3-phase power measurement.

BC9191 incorporates controller and I/O for Building Automation

Bottom Line:-

Beckhoff showcased the flexibility and performance of their products for building automation systems in their new USA headquarters.  This is not surprising because their products have been used for this purpose in a number of large projects already. Around the world, Beckhoff controllers and software are used for BAS applications in some interesting buildings including Maple Leaf Square in Toronto, Allianz Arena in Munich, and Microsoft Technology Center in Cologne.
The building automation industry has yet to embrace the openness of the IEC 61131-3 software standard for the type of control that is illustrated in this application.