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

2. About Fairmount Automation
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)
Product
Development
Engineering
Services
Andres and Gary founded the company in 1996 to respond to a U.S. Navy need to modernize aging pneumatic control systems.
The NAVY knew that they needed to make the leap to microprocessor based controllers but had special requirements that could not be met by commercial device.
Andres and Gary took on the challenge, and five months after starting demonstrated a working prototype to Navy engineers which was very well received.
Within one year of that first order they were able to pay off their start-up debts and begin to draw a salary. We’ve been able to grow the business steadily since then while maintaining profitability and retaining 100% ownership.
The company designs and manufactures control platforms, operates an application engineering and services group, and is very active in new technology development for to US NAVY
We’re here today to discuss our hybrid controller technology and a unique and exciting new approach to hybrid control that we call Chameleon

3. DD(X) AFSS
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)

4. 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
Five months after starting we demonstrated a working prototype to Navy engineers which was very well received, and within one year we were operating a successful business.
Our first product…the FAC2000, initially installed in 1998, proved that we could deliver high performance control in a robust package that the NAVY needed
We were soon replacing a vast array of legacy controls in applications including:
Waste Heat Boilers
Distilling Plants
Steam Propulsion
Propulsion Boilers
USS John F Kennedy

5. Current Installed Base
Over 1500 Loops of Control
Aircraft Carriers
Amphibious Assault
Amphibious Transport
Destroyers
Cruisers
Frigates
Combat Support Ships
Submarine Supply Ships
Although we’re relative new-comers to ISA and the industrial sector, we not new to the world of automation & control.
Our products are currently being used in mission critical and severe applications through-out the US Navy.
We currently have over 1500 loops of control installed and operational across the fleet
Our equipment is used both to retrofit the existing Fleet and in new construction. We have equipment on nearly every ship class other than submarines. and nearly one in three surface ships uses a Fairmount Automation controller
Most U.S. Navy ships have an expected service life of years. The same service period is expected of our equipment.
In addition, we are currently working with one of the nations largest regional rail systems to retro-fit legacy rail car controls.
USS Boone

6. 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
Shaft Speed Indication
Our application experience comes from controlling a variety of machinery—primarily steam machinery— operating in the propulsion plants of Navy vessels.
Namely power generation machinery and the machinery that drive the primary movers for the ship. Clearly these applications are mission-critical.
One of the more common applications has been automatic boiler control, including combustion control, feed pump control, blowers and feed tanks.
Another notable application is control of the steam accumulators in the catapult systems that launch aircraft from carrier flight. Again, the application is critical to the ship’s mission—the purpose of an aircraft carrier of course is to run flight operations.
USS Ticonderoga

7. Chameleon: New Controller Platform
Point our the modular architecture
Snap together modules
Local HMI
Hot Swap
Active electronics on cover plate – optimal replacement unit

8. 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

10. 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

11. 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

12. FFG-28 Installation Pictures

13. 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

14. LHD-1 Installation Pictures

15. 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

16. 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

17. Manual Boiler Light-Off

18. 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

19. LPD-15 Installation Picture

20. 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

21. Key Characteristics: Packaging

22. 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

23. Key Characteristics: Modular Design

24. 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

25. 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
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

26. 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: lbs
Chameleon nodes 20 lbs, Mounting bars 10.5 lbs, Other 10 lbs

27. 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

28. CVN-21 MCMS I/O Drop Comparison
Assume example platform has 20,000 I/O points
Conventional I/O Drop
200 drops required
Volume: 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
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: ft3 per drop, 571 ft3 total
Weight: 16 lbs per drop, 12,800 lbs total
Estimated Cost: $4,500 per drop, $3.6MM total

29. 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

30. 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

31. 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!)

32. 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

33. 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)

34. 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

35. 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

36. 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

37. 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)

38. User-Configurable Modules (UCM-X)
Custom modules with buttons, displays, etc.
Use as junction box
Available in full or half size

39. 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 Certified Wireless Security
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

40. PAC Programming: Design Pad G3
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
Chameleon’s distributed processor architecture enables high speed control execution even with complex control schemas. It’s capable of executing loop and logic control in the sub 10 millisecond range, enabling it to provide high performance control for a broad range of applications.
Fast control response allows you to operate more safely closer to process limits, while providing tighter control. This means that you may be able to increase productivity and at the same time produce a higher quality product.
It seamlessly integrates loop, logic and state control, and uses variables with user defined tag names for ease of programming and diagnostics.
There are no compromises or limits to your ability to merge loop and logic control on one high performance package, and
we provide programming and simulation tools such as state diagrams that are specifically designed to make the integration of loop and logic simple and easy to use

41. Design Pad G3 Demonstration